Method for producing epoxy compound and catalyst composition for epoxidation reaction

ABSTRACT

A method of producing an epoxy compound, which comprises reacting hydrogen peroxide with a compound having a carbon-carbon double bond, in the presence of at least one of a tungsten compound and a molybdenum compound; and an onium salt comprising 20 or more carbon atoms and one or more of substituents convertible to a functional group containing an active hydrogen or a salt thereof.

TECHNICAL FIELD

The present invention relates to a method for producing a novel epoxycompound and a novel catalyst composition for an epoxidation reaction.

BACKGROUND ART

An epoxy compound is being widely utilized as an epoxy monomer workingout to a raw material of an epoxy resin or as a raw material of variouschemical products.

The epoxy resin is a resin obtained by curing an epoxy monomer by usingvarious curing agents. The epoxy resin is a resin excellent in themechanical property, water resistance, chemical resistance, heatresistance, electric property and the like and is used in a wide rangeof fields such as electronic material, optical material, buildingmaterial, adhesive, coating material, laminated plate, molding material,casting material and resist.

Recently, the increased integration in the electronic material field,for example, fields of semiconductor sealing material, printed wiringboard, build-up wiring board and solder resist, accompanies requirementto highly purify also a package material typified by an epoxy resin.Furthermore, in the optoelectronics-related field, highly advancedinformatization in recent years leads to the development of a techniqueutilizing optical signals so as to smoothly transmit and process vastamounts of information and amid this trend, development of a high-purityresin excellent in the transparency is demanded.

With such growing needs for a high-purity epoxy resin, high purificationis required also of the epoxy monomer working out to a material of theepoxy resin.

A glycidyl ether compound as a representative epoxy monomer, forexample, a compound obtained by fusing a glycidyl oxy group to phenols,naphthols, bisphenol A, etc., is excellent in the heat resistance,adhesiveness, chemical resistance, electric properties, mechanicalproperties and the like and therefore, is an industrial material findingmany applications such as adhesive, molding material, sealing materialand coating material when crosslinked/cured by a curing agent. As theproduction method of the glycidyl ether compound, in the case of usingphenols as the raw material, a method of reacting epichlorohydrin withthe raw material phenols is most widely employed. A specific method forsynthesizing a glycidyl ether by using epichlorohydrin is represented,for example, by the following reaction formula:

However, in the epoxy compound obtained by the above-described method, achlorine atom derived from epichlorohydrin is mixed as an impurity inthe form of being chemically bonded to the compound. Therefore, thechlorine concentration in the epoxy compound is high. Specifically,chlorine is usually contained at a concentration of 1,000 ppm or more.When an epoxy resin produced from an epoxy compound (epoxy monomer)having such a high chlorine concentration is used for an IC sealingmaterial, there is a problem that corrosion or breakage of wiring islikely to occur due to refinement of the circuit for high integration.

To avoid such a problem, an epoxidation method not using epichlorohydrinis demanded. As the production method to meet this demand, a method ofcondensing an allyl alcohol by the use of a palladium catalyst to forman allyl ether and then obtaining an epoxy compound by the use ofhydrogen peroxide or an organic peroxide has been advocated (see, forexample, Patent Document 1). However, this method is not a practicalmethod, because the palladium is very expensive and for preventing theresidual palladium from contacting with an oxide such as peroxide todecompose the peroxide, a cumbersome process of purifying and removingthe palladium is necessary.

A method of producing an allyloxy form with a low chlorine content andoxidizing the allyloxy form to effect conversion to an epoxy compound,thereby synthesizing a glycidyl ether having a low chlorine content, hasbeen recently developed (see, for example, Patent Documents 2 and 3).

The epoxidation reaction employed in this production method is generallyperformed by allowing onium salts such as ammonium salt and at leasteither a tungsten compound or a molybdenum compound to exist togetherand using hydrogen peroxide as an oxidant (epoxidizing agent) (see, forexample, Non-Patent Documents 1 to 3).

This epoxidation reaction generates only water as a byproduct andtherefore, is a clean reaction producing less waste, compared with anepoxidation reaction using an organic peroxide typified by peraceticacid. In addition, since aqueous hydrogen peroxide of 30 to 45% is used,the procurement and handling are easy and simple.

However, in this epoxidation reaction, the oxidant is prepared using, asan onium salt usually allowed to coexist as a catalyst, an ammonium salthaving a long-chain alkyl group, such as methyltrioctylammoniumchloride, or a pyridinium salt having a long-chain alkyl group, such ascetylpyridinium salt. The onium salt having a long-chain alkyl group hasa high distribution factor to an organic solvent and poses a problemthat it is very difficult to, after the reaction, separate and purifythe epoxy compound dissolved in the organic phase from the catalystcomposition-derived components, specifically, tungsten, an onium salt,and an onium salt-derived nitrogen-containing compound. Furthermore,when tungsten, a nitrogen-containing compound and the like are removedby a method such as recrystallization and suspension-washing, there is aproblem that the purification yield (recovery percentage) of the epoxycompound is low.

Therefore, catalyst-derived heavy metal components such as tungsten andmolybdenum, or ionic compounds such as onium salt, remain in theobtained epoxy compound. These components or compounds remain also in anepoxy resin produced from the epoxy compound and adversely affect theproduct.

Specifically, it has been reported that in the case where a heavy metalsuch as tungsten remains in the epoxy compound, an epoxy resin producedusing the epoxy compound develops significant coloration when leftstanding under high-temperature conditions (see, for example, PatentDocument 4). Also, in the case of using the epoxy resin for anelectronic material, a halogen such as chlorine remaining in the epoxycompound gives rise to corrosion of wiring, and the remaining metal orionic compound such as onium salt gives rise to short circuit orcorrosion of wiring.

As the method for solving this problem, several methods have beenreported.

For example, in Patent Document 5 or 6, a method where, after theepoxidation ration, the ammonium salt is absorbed and removed by using,as an adsorbent, an ion-exchange resin, a metal oxide or the like, isstudied.

Also, in Patent Documents 7 and 8 and Non-Patent Document 4, a methodwhere the ammonium salt employed for the epoxidizing agent is used inthe state of being supported on a resin, silica gel or the like and thenseparated/recovered by filtration, is studied.

In Patent Document 9, a method where an ammonium salt used as thecatalyst is precipitated after the epoxidation reaction, is studied.

In addition, in Patent Document 10, a method of disproportionating thecatalyst is studied.

Furthermore, in Patent Document 11, a method of removing an ammoniumsalt by binding a magnetic material thereto is studied.

RELATED ART Patent Document

-   Patent Document 1: JP-T-10-511721 (the term “JP-T” as used herein    means a published Japanese translation of a PCT patent application)-   Patent Document 2: JP-A-2011-213716 (the term “JP-A” as used herein    means an “unexamined published Japanese patent application”)-   Patent Document 3: International Publication No. 2011/019061-   Patent Document 4: JP-A-2009-185274-   Patent Document 5: JP-A-2010-70480-   Patent Document 6: JP-A-2010-235649-   Patent Document 7: JP-A-2002-69079-   Patent Document 8: JP-A-2001-17863-   Patent Document 9: JP-A-2010-83836-   Patent Document 10: International Publication No. 2004/096440-   Patent Document 11: JP-A-2007-301466

NON-PATENT DOCUMENT

-   Non-Patent Document 1: J. Org. Chem., vol. 53 pp. 1553-1557 (1988)-   Non-Patent Document 2: J. Org. Chem., vol. 53 pp. 3587-3595 (1988)-   Non-Patent Document 3: Bull. Chem. Soc. Jpn., 70, 4 (1997)-   Non-Patent Document 4: Journal of the American Chemical Society,    Vol. 90, pp. 5956-5957 (1975)

SUMMARY OF THE INVENTION Problems that the Invention is to Solve

However, in the method described in Patent Document 5 or 6, an adsorbentmust be charged in an amount of 15 wt % or more based on the epoxycompound and in addition, an operation of separating the adsorbent isrequired.

Furthermore, use of an adsorbent leads to a fear of reduction inproductivity due to adsorption loss of the epoxy compound to theadsorbent or elution and mixing of an ion exchange resin-derived organicimpurity or a metal oxide-derived metal.

In the case of fixing the catalyst component on a support as describedin Patent Documents 7 and 8 or Non-Patent document 4, the activity ofthe catalyst is reduced, and there arises a new problem, for example,that a large amount of a catalyst is required, the usable solvent islimited so as to avoid swelling of the resin on which the catalyst issupported, or the catalyst thermal stability deteriorates.

In Patent Document 9, it is stated that the tungsten amount can bereduced only to about 600 ppm at the most by a precipitation operationalone.

In the method described in Patent Document 10, the disproportionationinvolves a problem, for example, that the reaction rate is reduced orthe method cannot be applied to a monomer having good crystallinity.

The method described in Patent Document 11 has a problem that thecatalyst synthesis is cumbersome.

In this way, it has been difficult with all of those conventionalmethods to produce an epoxy compound reduced in the content of a heavymetal component such as tungsten or a nitrogen-containing compoundderived from an onium salt.

The oxide such as hydrogen peroxide causes decomposition, heatgeneration, oxygen generation or the like upon contact with a foreignmaterial such as metal, activated carbon, silica gel and glass piece andtherefore, mixing of such a foreign material in the epoxidation reactionsolution is preferably avoided, but it is difficult to completelyprevent mixing of a foreign material in the production process, andtaking safety measures is required.

An object of the present invention is to provide a method for producingan epoxy compound having a very small content of a heavy metal such astungsten, preferably further having a small content of an oniumsalt-derived nitrogen-containing compound (hereinafter, simply referredto as the nitrogen content), more preferably further having a smallchlorine content, without requiring a cumbersome purification processand the like.

Means for Solving the Problems

The present inventors have designed a compound by incorporating a newconcept, that is, introduction of a structure convertible to an easilyremovable compound, into an onium salt caused to coexist as a catalyst,and used the compound for the epoxidation reaction.

Specifically, the reaction was performed in coexistence of an onium salthaving, in the molecule, at least one or more substituents that areconvertible to an active hydrogen-containing functional group or a saltthereof. As a result, it has been found that an objective epoxy compoundis obtained and when conversion to an active hydrogen-containingfunctional group or a salt thereof is effected after the epoxidationreaction, the epoxidizing agent-derived components are separated andremoved from the epoxy compound, resulting in obtaining an epoxycompound with high purity. The present invention has been accomplishedbased on this finding.

That is, the gist of the present invention resides in the followings.

[1] A method for producing an epoxy compound, comprising reactinghydrogen peroxide with a compound having a carbon-carbon double bond inthe presence of at least one of a tungsten compound and a molybdenumcompound; and an onium salt having 20 or more carbon atoms andcontaining one or more substituents convertible to an activehydrogen-containing functional group or a salt thereof.[2] The method for producing an epoxy compound as described in the [1]above, wherein said active hydrogen-containing functional group is ahydroxyl group, a carboxyl group, an amino group, a mercapto group, asulfonic acid group or a phosphoric acid group.[3] The method for producing an epoxy compound as described in the [1]or [2] above, wherein at least one of phosphoric acids and phosphonicacids (excluding an onium salt) is further allowed to coexist in saidreaction.[4] The method for producing an epoxy compound as described in any oneof the [1] to [3] above, wherein said reaction is a two-phase reactionof an aqueous phase and an organic phase and the pH of said aqueousphase is from 2 to 6.[5] The method for producing an epoxy compound as described in any oneof the [1] to [4] above, wherein said onium salt is an ammonium salt, apyridinium salt, an imidazolinium salt or a phosphonium salt.[6] The method for producing an epoxy compound as described in any oneof the [1] to [5] above, wherein said substituent convertible to anactive hydrogen-containing functional group or a salt thereof is analkoxycarbonyl group or an acyloxy group.[7] The method for producing an epoxy compound as described in any oneof the [1] to [6] above, wherein said onium salt is a compoundrepresented by any one of the following formulae (1) to (3):

(in formulae (1) to (3), each of any one or more of R¹ to R⁴, any one ormore of R⁵ to R¹⁰ and any one or more of R¹¹ to R¹⁵ independentlyrepresents —Y—CO—O—Z or —Y—O—CO—Z (wherein Y represents a direct bond ora divalent aliphatic hydrocarbon group having a carbon number of 1 to25, in which a part of carbon atoms may be substituted with a heteroatomand which may have a substituent, and Z represents a monovalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, or amonovalent aromatic hydrocarbon group having a carbon number of 4 to 25,which may have a substituent),

each of R¹ to R⁵, R¹¹ and R¹³, when these are not —Y—CO—O—Z or—Y—O—CO—Z, independently represents an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom and which may have a substituent, or a benzyl group,

each of R⁶ to R¹⁰, R¹², R¹⁴ and R¹⁵, when these are not —Y—CO—O—Z or—Y—O—CO—Z, independently represents a hydrogen atom, a halogen atom, acyano group, a nitro group, an alkyl group having a carbon number of 1to 25, in which a part of carbon atoms may be substituted with aheteroatom and which may have a substituent, a phenyl group, a phenoxygroup, a benzyl group, an N-alkylcarbamoyl group or an N-alkylsulfamoylgroup,

R¹ to R¹⁵ may combine in the same compound to form a ring,

provided that the total number of carbon atoms contained in R¹ to R⁴ informula (1) is 20 or more, the total number of carbon atoms contained inR⁵ to R¹⁰ in formula (2) is 15 or more, and the total number of carbonatoms contained in R¹¹ to R¹⁵ in formula (3) is 17 or more,

and

X⁻ represents a monovalent anion).

[8] The method for producing an epoxy compound as described in any oneof the [1] to [7] above, wherein in said production method, after thereaction, said substituent convertible to an active hydrogen-containingfunctional group or a salt thereof is hydrolyzed with a basic compound.[9] The method for producing an epoxy compound as described in any oneof the [1] to [8] above, wherein said compound having a carbon-carbondouble bond is washed with an acidic aqueous solution and then subjectedto the reaction.[10] The method for producing an epoxy compound as described in any oneof the [1] to [8] above, wherein said compound having a carbon-carbondouble bond is washed with an aqueous chelating agent solution and thensubjected to the reaction.[11] The method for producing an epoxy compound as described in any oneof the [1] to [10] above, wherein in said production method, a chelatingagent is allowed to coexist in the reaction.[12] A method for producing an epoxy resin by polymerizing an epoxycompound, the production method of an epoxy resin comprising: producingan epoxy compound by the method claimed in any one of the [1] to [11]above; and polymerizing the epoxy compound obtained above.[13] A catalyst composition for an epoxidation reaction, comprising:

at least one of a tungsten compound and a molybdenum compound, and

an onium salt having a carbon number of 20 or more and containing one ormore substituents convertible to an active hydrogen-containingfunctional group or a salt thereof.

[14] The catalyst composition for an epoxidation reaction as describedin the [13] above, wherein said active hydrogen-containing functionalgroup is a hydroxyl group, a carboxyl group, an amino group, a mercaptogroup, a sulfonic acid group or a phosphoric acid group.[15] The catalyst composition for an epoxidation reaction as describedin the [13] or [14] above, which further comprises at least one ofphosphoric acids and phosphonic acids (excluding an onium salt).[16] The catalyst composition for an epoxidation reaction as describedin any one of the [13] to [15] above, wherein said onium salt is anammonium salt, a pyridinium salt, an imidazolinium salt or a phosphoniumsalt.[17] The catalyst composition for an epoxidation reaction as describedin any one of the [13] to [16] above, wherein said substituentconvertible to an active hydrogen-containing functional group or a saltthereof is an alkoxycarbonyl group or an acyloxy group.[18] The catalyst composition for an epoxidation reaction as describedin any one of the [13] to [17] above, which further comprises acarboxylic acid (excluding an onium salt having a carboxy group).[19] The catalyst composition for an epoxidation reaction as describedin any one of the [13] to [18] above, wherein said onium salt is acompound represented by any one of the following formulae (1) to (3):

(in formulae (1) to (3), each of any one or more of R¹ to R⁴, any one ormore of R⁵ to R¹⁰ and any one or more of R¹¹ to R¹⁵ independentlyrepresents —Y—CO—O—Z or —Y—O—CO—Z (wherein Y represents a direct bond ora divalent aliphatic hydrocarbon group having a carbon number of 1 to25, in which a part of carbon atoms may be substituted with a heteroatomand which may have a substituent, and Z represents a monovalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, or amonovalent aromatic hydrocarbon group having a carbon number of 4 to 25,which may have a substituent),

each of R¹ to R⁵, R¹¹ and R¹³, when these are not —Y—CO—O—Z or—Y—O—CO—Z, independently represents an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom and which may have a substituent, or a benzyl group,

each of R⁶ to R¹⁰, R¹², R¹⁴ and R¹⁵, when these are not —Y—CO—O—Z or—Y—O—CO—Z, independently represents a hydrogen atom, a halogen atom, acyano group, a nitro group, an alkyl group having a carbon number of 1to 25, in which a part of carbon atoms may be substituted with aheteroatom and which may have a substituent, a phenyl group, a phenoxygroup, a benzyl group, an N-alkylcarbamoyl group or an N-alkylsulfamoylgroup,

R¹ to R¹⁵ may combine in the same compound to form a ring,

provided that the total number of carbon atoms contained in R¹ to R⁴ informula (1) is 20 or more, the total number of carbon atoms contained inR⁵ to R¹⁶ in formula (2) is 15 or more, and the total number of carbonatoms contained in R¹¹ to R¹⁵ in formula (3) is 17 or more,

and

X⁻ represents a monovalent anion).

[20] An onium salt represented by the following formula (8) to (10),(12) or (31):

(in formulae (8) to (10), (12) and (31), R²⁰ represents a hydrogen atom,a halogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an alkoxycarbonyl group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group; each of R²¹ to R²³ independently represents analkyl group having a carbon number of 1 to 25, in which a part of carbonatoms may be substituted with a heteroatom, or a benzyl group; R²⁰ toR²³ may combine in the same compound to form a ring; k represents aninteger of 1 to 4;

each of R³¹ and R³² independently represents a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom;

R³³ represents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25, which may have a substituent;

provided that a plurality of k, R²⁰ or R³¹ present in the same compoundmay be the same or different and the total number of carbon atomscontained in the cation moiety in the formulae is 20 or more; and

X⁻ represents a monovalent anion).

[21] A composition comprising:

an epoxy compound α represented by the following formula (32), and

a compound β having a structure where one or more glycidyl groupscontained in said epoxy compound α are substituted with a3-acyloxy-2-hydroxypropyl group (wherein said acyl group is a grouprepresented by —CO—R³⁵ or —CO—Z):

(in formula (32), G represents a glycidyl group (2,3-epoxypropanylgroup), and said glycidyl group may be substituted with an alkyl group,a phenyl group or an alkoxycarbonyl group;

A²⁰¹ represents an (m201+1)-valent aromatic or aliphatic hydrocarbongroup that may have a substituent, A²⁰² represents a divalent aromaticor aliphatic hydrocarbon group that may have a substituent, and A²⁰³represents an (m203+2)-valent aromatic or aliphatic hydrocarbon groupthat may have a substituent;

each of X²⁰¹ and X²⁰² independently represents a direct bond or adivalent linking group that may have a substituent;

p201 represents 0 or 1;

each of m201 and m203 independently represents an integer of 1 or more;

n201 represents an integer of 1 or more, n202 represents 0 or an integerof 1 or more, and n203 represents 0 or 1;

provided that in the case of n202=n203=0, when p201=0, A²⁰¹ becomesm201-valent and when p201=1, X²⁰¹ is a hydrogen atom or a monovalentgroup; and

provided that a plurality of G, A²⁰¹, A²⁰², X²⁰¹, X²⁰², m201 or p201contained in one molecule may be the same or different),

wherein in —CO—R³⁵ and —CO—Z,

Z represents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25, which may have a substituent, and

R³⁵ represents a group represented by any one of the following formulae(18) to (20):

(in formula (18),

R⁴¹ represents a direct bond or a divalent aliphatic hydrocarbon grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom, and

each of R⁴² to R⁴⁴ independently represents an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, or a benzyl group;

in formula (19),

any one of R⁴⁵ to R⁵⁰ represents a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom,

provided that in the case where R⁴⁵ is a direct bond or a divalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, each of R⁴⁶to R⁵⁰ independently represents a hydrogen atom, a halogen atom, a cyanogroup, a nitro group, an alkyl group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom, aphenyl group, a phenoxy group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group, and

in the case where any one of R⁴⁶ to R⁵⁰ is a direct bond or a divalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, each of theother four independently represents a hydrogen atom, a halogen atom, acyano group, a nitro group, an alkyl group having a carbon number of 1to 25, in which a part of carbon atoms may be substituted with aheteroatom, a phenyl group, a phenoxy group, a benzyl group, anN-alkylcarbamoyl group or an N-alkylsulfamoyl group, and R⁴⁵ representsan alkyl group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom, or a benzyl group;and

in formula (20),

any one of R⁵¹ to R⁵⁵ represents a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom,

provided that in the case where either one of R⁵¹ and R⁵³ is a directbond or a divalent aliphatic hydrocarbon group having a carbon number of1 to 25, in which a part of carbon atoms may be substituted with aheteroatom, the other represents an alkyl group having a carbon numberof 1 to 25, in which a part of carbon atoms may be substituted with aheteroatom, or a benzyl group, and each of R⁵², R⁵⁴ and R⁵⁵independently represents a hydrogen atom, a halogen atom, a cyano group,a nitro group, an alkyl group having a carbon number of 1 to 25, inwhich a part of carbon atoms may be substituted with a heteroatom, aphenyl group, a phenoxy group, a benzyl group, an N-alkylcarbamoyl groupor an N-alkylsulfamoyl group, and

in the case where any one of R⁵², R⁵⁴ and R⁵⁵ is a direct bond or adivalent aliphatic hydrocarbon group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom,each of the other two independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an N-alkylcarbamoyl group or an N-alkylsulfamoyl group, and eachof R⁵¹ and R⁵³ independently represents an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a benzyl group;

the total number of carbon atoms contained in R⁴¹ to R⁴⁴ in formula (18)is 20 or more, the total number of carbon atoms contained in R⁴⁵ to R⁵⁰in formula (19) is 15 or more, and the total number of carbon atomscontained in R⁵¹ to R⁵⁵ in formula (20) is 17 or more; and

R⁴¹ to R⁵⁵ may combine in the same compound to form a ring).

[22] The composition as described in the [21] above, wherein said epoxycompound α is a compound represented by any one of the followingformulae (13) to (15):

(A¹)-(OG)_(m1)  (13)

(in formula (13), G represents a glycidyl group (2,3-epoxypropanylgroup), and said glycidyl group may be substituted with an alkyl group,a phenyl group or an alkoxycarbonyl group; A¹ represents an m1-valentaromatic or aliphatic hydrocarbon group that may have a substituent; andm1 represents an integer of 1 or more; provided that a plurality of Gcontained in one molecule may be same or different);

(GO)_(m2)-(A²¹)-[X²-(A²²)]_(n2)—X²-(A²¹)-(OG)_(m2)  (14)

(in formula (14), G represents a glycidyl group, and said glycidyl groupmay be substituted with an alkyl group, a phenyl group or analkoxycarbonyl group; A²¹ represents an (m2+1)-valent aromatic oraliphatic hydrocarbon group that may have a substituent; A²² representsa divalent aromatic or aliphatic hydrocarbon group that may have asubstituent; the A²¹ and A²² connected through X² or a plurality ofadjacent A²² may combine with each other to form a ring; X² represents adirect bond or a divalent linking group that may have a substituent; m2represents an integer of 1 or more; and n2 represents 0 or an integer of1 or more; provided that a plurality of G, A²¹, A²², X² or m2 containedin one molecule may be same or different);

H—[(A³(OG)_(m3))—X³]_(n3)—H  (15)

(in formula (15), G represents a glycidyl group, and said glycidyl groupmay be substituted with an alkyl group, a phenyl group or analkoxycarbonyl group; A³ represents an (m3+2)-valent aromatic oraliphatic hydrocarbon group that may have a substituent; X³ represents adirect bond, an alkylene group that may have a substituent, or—R⁴¹-phenylene-R⁴²-, wherein each of R⁴¹ and R⁴² independentlyrepresents an alkylene group; m3 represents an integer of 1 or more; andn3 represents an integer of 2 or more; provided that a plurality of G,A³, X³ or m3 contained in one molecule may be same or different).[23] The composition as described in the [21] or [22] above, wherein theabundance ratio of said compound β to said epoxy compound α contained insaid composition is from 0.05 to 10.0 mol %.[24] The composition as described in any one of the [21] to [23] above,wherein said compound β is a compound where in formula (13) to (15) or(32), one or more -OG groups are substituted with a group represented bythe following formula (16) or (17) and one or more -OG groups may besubstituted with a group represented by the following formula (33):

(in formula (16), R³⁵ represents a group represented by any one of theformulae (18) to (20) as described above; and

in formula (17), Z represents a monovalent aliphatic hydrocarbon grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom, or a monovalent aromatic hydrocarbongroup having a carbon number of 4 to 25, which may have a substituent).

Advantage of the Invention

According to the present invention, an epoxy compound having a verysmall content of a heavy metal such as tungsten can be obtained. Also, ahigh-purity epoxy compound having very small onium salt and chlorinecontents can be produced by a simple method without requiring acumbersome process such as purification.

Furthermore, the production method of the present invention can beapplied also to the production of an epoxy compound incapable of beingpurified by distillation or crystallization and has excellent generalversatility. In the case where an epoxy compound obtained by the methodof the present invention is used for an electronic material, an opticalmaterial, etc. or used as a medical/agrochemical raw material, problemsattributable to impurities can be reduced, and a high-purity andhigh-quality product can be obtained.

In addition, even if a foreign material such as metal, activated carbon,silica gel and glass piece is mixed in the reaction system,decomposition, heat generation, oxygen generation and the like can besuppressed, and in turn, an epoxy compound can be safely produceddespite use of hydrogen peroxide.

MODE FOR CARRYING OUT THE INVENTION

The mode for carrying out the present invention is described in detailbelow, but the constituent requirements described below are an exampleof the embodiment of the present invention, and the present invention isnot limited to the following contents and can be implemented by makingvarious modifications therein without departing from the gist of thepresent invention.

The production method of an epoxy compound of the present invention ischaracterized by reacting hydrogen peroxide with a compound having acarbon-carbon double bond (hereinafter, sometimes referred to as “olefincompound”) in the presence of at least either a tungsten compound or amolybdenum compound and an onium salt having 20 or more carbon atoms andcontaining one or more substituents that are convertible to an activehydrogen-containing functional group or a salt thereof. In thedescription of the present invention, the “at least either a tungstencompound or a molybdenum compound” is sometimes referred to as“catalytic metal component”; the “onium salt having 20 or more carbonatoms and containing one or more substituents that are convertible to anactive hydrogen-containing functional group or a salt thereof” issometimes simply referred to as “onium salt”; the composition containingthese “catalytic metal component” and “onium salt” is sometimes referredto as “catalyst composition for an epoxidation reaction” or simply as“catalyst composition”; and the composition obtained by oxidizing thecatalyst composition above with hydrogen peroxide is sometimes referredto as “reaction active species composition”.

In the present invention, hydrogen peroxide acts as an oxidant foroxidizing the catalyst composition.

As the hydrogen peroxide, aqueous hydrogen peroxide is usually used, anda commercially available aqueous hydrogen peroxide may be used directlyor after dilution with water. The concentration of the aqueous hydrogenperoxide is usually 1 wt % or more, preferably 20 wt % or more, andusually 60 wt % or less, and considering the availability, safetyproblem, productivity and the like, is more preferably from 30 to 45 wt%.

The amount of the hydrogen peroxide used is usually 0.5 times by mol ormore, preferably 1 times by mol or more, and usually 10 times by mol orless, preferably 3 times by mol or less, per mol of the double bond inthe olefin compound used as a raw material.

<Catalyst Composition>

The catalyst composition of the present invention indicates a mixture ofthe later-described catalytic metal component and an onium salt. Themethod for preparing the catalyst composition may be appropriatelyselected according to the reactant or its reactivity and is notparticularly limited, but either a method of mixing a catalytic metalcomponent and an onium salt in the reaction system or a method of mixinga catalytic metal component and an onium salt outside the reactionsystem and using the mixture for the reaction may be employed. Also, themethod for adding the later-described phosphoric acids may be either amixing method in the reaction system or a previous mixing method outsidethe reaction system.

In the case of mixing a catalytic metal component and an onium salt inthe reaction system, the mixing method and mixing order are notparticularly limited, but specifically, the later-described catalyticmetal component and an onium salt are usually added to a reaction systemcontaining an olefin compound, whereby the composition can be prepared.The addition order thereof is not particularly limited, and either acatalytic metal component or an onium salt may be added first, or thesemay be added simultaneously.

Also, a catalytic metal component and an onium salt may be previouslymixed outside the reaction system and then used. In this case, themixing method, mixing order, and use mode of the mixture are notparticularly limited, but a catalytic metal component and an onium saltmay be mixed and used directly, or a composite of a catalyst componentand an onium salt, which is produced in the catalyst composition, may beisolated and used. Among others, a method of mixing a catalytic metalcomponent and an onium salt and using the mixture directly withoutperforming isolation or activation is easy and therefore, preferable.

It is considered that in the reaction system, a catalytic metalcomponent and an onium salt in the catalyst composition of the presentinvention form a composite, preferably further form a composite with atleast either one of the later-described phosphoric acids and phosphonicacids, and this composite is oxidized with hydrogen peroxide and becomesa “reaction active species composition” to act as a reaction activespecies of the epoxidation reaction in the present invention.

Also, the reaction active species composition may be activated bypartially adding hydrogen peroxide to the above-described mixture of acatalytic metal component and an onium salt (that is, the “catalystcomposition”) and then added to the reaction system.

<Catalytic Metal Component>

As the catalytic metal component of the present invention, at leasteither a tungsten compound or a molybdenum compound is used.Specifically, a tungstic acid or a salt of tungstic acid (hereinafterreferred to as tungstic acids), a molybdic acid or a salt of molybdicacid (hereinafter referred to as molybdic acids), or a mixture thereofis used. Among these, tungstic acids are preferred in view of cost andavailability.

The tungstic acids specifically include, for example, tungstic acid; atungstate such as sodium tungstate, potassium tungstate, calciumtungstate and ammonium tungstate; a hydrate of the tungstate above; aphosphotungstic acid such as 12-tungstophosphoric acid and18-tungstophosphoric acid; a silicotungstic acid such as12-tungstosilicic acid; a 12-tungstoboric acid; and metallic tungsten.Among others, tungstic acid, a tungstate and a phosphotungstic acid arepreferred, and in view of availability, tungstic acid, sodium tungstate,calcium tungstate and 12-tungstophosphoric acid are more preferred.

The molybdic acids include molybdic acid: a molybdate such as sodiummolybdate, potassium molybdate and ammonium molybdate; and a hydrate ofthe molybdate above.

Among these tungstic acids and molybdic acids, tungstic acid, sodiumtungstate and a hydrate thereof, and calcium tungstate and a hydratethereof are preferred in view of availability, and tungstic acid is morepreferred in view of ease of recovery and regeneration, tungstic acid ismore preferred.

One of these catalytic metal components may be used alone, or two ormore thereof may be used in appropriate combination.

The amount of the catalytic metal component used in the presentinvention can be appropriately adjusted according to the property of thesubstrate or the like employed and is not particularly limited but, interms of the catalytic metal atom (for example, in the case of tungsticacids, in terms of tungsten atom), is usually 0.001 mol or more,preferably 0.005 mol or more, more preferably 0.01 mol or more, andusually 1.0 mol or less, preferably 0.50 mol or less, more preferably0.10 mol or less, per mol of the double bond contained in the olefincompound used as a raw material. If the amount used is less than thislower limit, the reaction may not proceed, whereas if the amount usedexceeds the upper limit above, this may be disadvantageous in view ofcost.

<Onium Salt>

The onium salt used in the present invention is an onium salt having 20or more carbon atoms and containing one or more substituents that areconvertible to an active hydrogen-containing functional group or a saltthereof.

This onium salt has properties of being oil-soluble at the time ofepoxidation reaction, soluble in a reaction solvent, distributed in theorganic phase side when the system is separated into an aqueous phaseand an organic phase, and stable under epoxidation reaction conditionsor kept from extreme reduction in the catalytic ability even when thestructure is changed during the epoxidation reaction. In order to besoluble in a reaction solvent and distributed in the organic phase, highlipophilicity is required and for this purpose, the onium salt mustcontain 20 or more carbon atoms.

Also, the onium salt is characterized by containing a substituentcapable of, after the completion of epoxidation reaction, affordingconversion to a water-soluble compound having an activehydrogen-containing functional group or a salt by a simple method undermild conditions causing no decomposition of the epoxy group of an epoxycompound produced by the reaction.

The cation species (hereinafter, simply referred to as “onium”) of theonium salt for use in the present invention is not particularly limitedas long as it satisfies the above-described conditions. That is, theonium is an onium having 20 or more carbon atoms and containing one ormore substituents that are convertible to an active hydrogen-containingfunctional group or a salt thereof, and specific oniums include usuallyammonium, a nitrogen-containing heterocyclic quaternary cation suchpyridinium and imidazolinium, phosphonium, etc. (in other words, theonium salt includes an ammonium salt, a pyridinium salt, animidazolinium salt, and a phosphonium salt). Because of ease ofsynthesis, ammonium, pyridinium or imidazolinium is preferably used.

The anion species of the onium salt for use in the present invention isnot particularly limited but is a monovalent anion and specificallyincludes a hydrogen sulfate ion, a monomethyl sulfate ion, a halide ion,a nitrate ion, an acetate ion, a hydrogen carbonate ion, a dihydrogenphosphate ion, a sulfonate ion, a carboxylate ion, a hydroxide ion, etc.From the standpoint that the anion species does not attach to the epoxygroup of an epoxy compound as a reaction product or to the carbon-carbondouble bond of an olefin compound as a raw material compound or thepreparation is easy, the anion is preferably a monomethyl sulfate ion, ahydrogen sulfate ion, an acetate ion, a dihydrogen phosphate ion or ahydroxide ion,

The onium salt for use in the present invention contains, in its oniummoiety, one or more substituents that are convertible to an activehydrogen-containing functional group or a salt thereof. The activehydrogen-containing functional indicates a functional group capable ofdissociating to release a hydrogen ion, and the salt thereof indicates acompound where another cation species becomes a counter anion instead ofthe dissociated hydrogen ion. The active hydrogen-containing functionalgroup is not particularly limited and is preferably a hydroxyl group, acarboxyl group, an amino group, a mercapto group, a sulfonic acid group,a phosphoric acid group, or a salt thereof, more preferably a carboxylgroup or a hydroxyl group, still more preferably a hydroxyl group.

The substituent convertible to an active hydrogen-containing functionalgroup or a salt thereof means a substituent that can be converted to theabove-described active hydrogen-containing functional group or a saltthereof by applying at least either a physical operation or a chemicaloperation. Specifically, the substituent indicates a substituent thatcan be converted by a reaction with a base, a reaction with an acid, achemical reaction such as catalytic hydrogenation, heating, aphotoreaction, an enzyme reaction, microwave irradiation, etc. Thesubstituent is preferably a substituent convertible under mildconditions, more preferably a substituent convertible under theconditions not involving a reaction with the epoxy group, still morepreferably, for example, an alkoxycarbonyl group, an acyloxy group, acarbamate group, an imide group, an amide group, an ether group, a silylether group, an acetal group, a ketal group, a hemiacetal group, asulfonic acid ester group, a thioether group, a thioester group, athiocarbamate group, a thioacetal group, a phosphoric acid ester group,or a benzyl ether group.

In addition, a substituent having a structure where in the process ofthe onium salt-containing reaction active species composition reactingwith an olefin compound, an active hydrogen-containing functional groupor a salt thereof is produced from the above-described substituentconvertible to an active hydrogen-containing functional group or a saltthereof, for example, a ketone group (ketone structure) that areconverted to an ester group by a Baeyer-Villiger oxidation reactionduring the reaction above, a nitrile group and a benzyl group, is alsoencompassed, as an example, by the substituent convertible to an activehydrogen-containing functional group or a salt thereof.

Among others, an alkoxy carbonyl group and an acyl group are preferred,because these can be hydrolyzed simply by the contact with a basicaqueous solution without decomposing the epoxy group and converted to ahydroxyl group, a carboxylic acid group or a salt thereof and theirsynthesis is also easy. An alkoxycarbonyl is more preferred.

The number of the above-described substituents is 1 or more but from thestandpoint of removal efficiency in the washing, is preferably 2 ormore.

The onium salt-containing reaction active species composition for use inthe present invention is preferably dissolved in at least either anolefin compound as a reaction raw material or a solvent used at the timeof epoxidation reaction. Therefore, the onium salt must have a highlylipophilic moiety in its structure. The specific structure or form isnot particularly limited as long as it does not inhibit the reaction andis stable to the epoxidation reaction or maintains the catalyticactivity even when the structure is changed during the epoxidationreaction. The structure may be any of an aliphatic group, an aromaticgroup and a compound having both groups, and the form may also be any oflinear, branched and cyclic structures. Furthermore, the structure maycontain, as a constituent atom, a heteroatom such as oxygen andnitrogen. It may be sufficient if both a compound produced by theafter-treatment, that is, a compound having a substituent convertible toan active hydrogen-containing functional group, and a compound composedof other moieties can be removed under the conditions not involvingdecomposition of the epoxy group.

As the onium salt for use in the present invention, an onium saltrepresented by any one of the following formulae (1) to (3) ispreferably used:

(in formulae (1) to (3), each of any one or more of R¹ to R⁴, any one ormore of R⁵ to R¹⁰ and any one or more of R¹¹ to R¹⁵ independentlyrepresents —Y—CO—O—Z or —Y—O—CO—Z (wherein Y represents a direct bond ora divalent aliphatic hydrocarbon group having a carbon number of 1 to25, in which a part of carbon atoms may be substituted with a heteroatomand which may have a substituent, and Z represents a monovalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, or amonovalent aromatic hydrocarbon group having a carbon number of 4 to 25,which may have a substituent),

each of R¹ to R⁵, R¹¹ and R¹³, when these members are not —Y—CO—O—Z or—Y—O—CO—Z, independently represents an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom and which may have a substituent, or a benzyl group,

each of R⁶ to R¹⁰, R¹², R₁₄ and R¹⁵, when these members are not—Y—CO—O—Z or —Y—O—CO—Z, independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom and which may have a substituent, a phenylgroup, a phenoxy group, a benzyl group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group,

R¹ to R¹⁵ may combine in the same compound to form a ring, or

when R¹ to R¹⁵ are an alkyl group having a carbon number of 1 to 25, inwhich a part of carbon atoms may be substituted with a heteroatom andwhich may have a substituent, each of these members may have, as thesubstituent, another onium salt represented by any one of formulae (1)to (3),

provided that the total number of carbon atoms contained in R¹ to R⁴ informula (1) is 20 or more, the total number of carbon atoms contained inR⁵ to R¹⁰ in formula (2) is 15 or more, and the total number of carbonatoms contained in R¹¹ to R¹⁵ in formula (3) is 17 or more,

and

X⁻ represents a monovalent anion).

In formula (1), any one or more of R¹ to R⁴ represents —Y—CO—O—Z or—Y—O—CO—Z. Also, the total number of carbon atoms contained in R′ to R⁴is 20 or more.

Similarly to formula (1), any one or more of R⁵ to R¹⁰ in formula (2)represents —Y—CO—O—Z or —Y—O—CO—Z. Also, the total number of carbonatoms contained in R⁵ to R¹⁰ is 15 or more.

Similarly, any one or more of R¹¹ to R¹⁵ in formula (3) represents—Y—CO—O—Z or —Y—O—CO—Z. Also, the total number of carbon atoms containedin R¹¹ to R¹⁵ is 17 or more.

Y represents a direct bond or a divalent aliphatic hydrocarbon grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom and which may have a substituent, andthe aliphatic hydrocarbon group may have any of linear, branched andcyclic structures.

The divalent aliphatic hydrocarbon group specifically includes a linearaliphatic hydrocarbon group such as methylene, ethylene, tetramethyleneand hexamethylene, a branched aliphatic hydrocarbon group formed byfurther bonding an alkyl chain to the hydrocarbon group above, and acyclic aliphatic hydrocarbon group such as cyclohexene. In the casewhere Y is a divalent aliphatic hydrocarbon group having a carbon numberof 1 to 25, a part of carbon atoms thereof may be substituted with aheteroatom. Specifically, the methylene group in the structure of such adivalent aliphatic hydrocarbon group may be substituted with aheteroatom-containing structure such as —O—, —S—, —SO—, —SO₂—, —NH—,—NR¹⁶⁻ (R¹⁶ represents a monovalent aliphatic hydrocarbon group having acarbon number of 1 to 25 or a monovalent aromatic hydrocarbon group),—CONR¹⁷— (R¹⁷ represents a hydrogen atom, a monovalent aliphatichydrocarbon group having a carbon number of 1 to 25 or a monovalentaromatic hydrocarbon group), —NHCONH—, —CONHCO— and —SO₂NR¹⁷— (R¹⁷ hasthe same meaning as above). Incidentally, the “hydrocarbon group inwhich a part of the carbon atoms may be substituted with a heteroatom”as used in the description of the present invention always has the samemeaning as above. Y is preferably ethylene, propylene, tetramethylene,hexamethylene or —CH₂CH₂—O—CH₂CH₂—.

In the case where Y is a divalent aliphatic hydrocarbon group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom and which may have a substituent, thesubstituent includes, for example, —O—CO—Z and —CO—O—Z (wherein Z hasthe same meaning as in formulae (1) to (3). In this case, each of thecompounds represented by formula (1) to (3), where any one of R¹ to R¹⁵is —Y—CO—O—Z or —Y—O—CO—Z, has —O—CO—Z or —CO—O—Z and additionally has—O—CO—Z or —CO—O—Z as the substituent of the aliphatic hydrocarbon groupin Y.

Z represents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25. The monovalent aliphatic hydrocarbon grouphaving a carbon number of 1 to 25 may have any of linear, branched andcyclic structures. This aliphatic hydrocarbon group specificallyincludes a linear aliphatic hydrocarbon group such as methyl, ethyl,propyl, butyl, hexyl butyl and octyl, a branched aliphatic hydrocarbonformed by further bonding an alkyl chain to the hydrocarbon group above,and a cyclic aliphatic hydrocarbon group such as cyclohexyl. Themonovalent aromatic hydrocarbon group having a carbon number of 4 to 25includes, for example, a monovalent benzene ring that may have an alkylgroup or a halogen atom as a substituent, and a naphthalene ring.

In the case of a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, a part of carbon atoms in the structure thereof maybe substituted with a heteroatom. Specifically, the methylene group inthe structure of the aliphatic hydrocarbon group may be substituted witha heteroatom-containing structure such as —NR¹⁶— (R¹⁶—O—, —S—, —SO—,—SO₂—, —NH—, represents a monovalent aliphatic hydrocarbon group havinga carbon number of 1 to 25 or a monovalent aromatic hydrocarbon group),—CONR¹⁷— (R¹⁷ represents a hydrogen atom, a monovalent aliphatichydrocarbon group having a carbon number of 1 to 25 or a monovalentaromatic hydrocarbon group), —NHCONH—, —CONHCO— and —SO₂NR¹⁷— (R¹⁷ hasthe same meaning as above).

The monovalent aromatic hydrocarbon group having a carbon number of 4 to25 includes, for example, a phenyl group, a benzyl group, and a naphthylgroup, and these groups may have a substituent including, for example, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an alkoxycarbonyl group, an N-alkylcarbamoyl group and anN-alkylsulfamoyl group. Among these, in view of productivity of theonium salt, a phenyl group is preferred.

In the case where Y of —Y—CO—O—Z in the formulae above represents ahydrocarbon group, the carbon number thereof is preferably 3 or more inview of stability of the onium salt during the epoxidation reaction.

The onium salts where R¹ to R¹⁵ are not —Y—CO—O—Z or —Y—O—CO—Z aredescribed below.

Out of R¹ to R¹⁵, each of R¹ to R⁵, R¹¹ and R¹³, when these members arenot —Y—CO—O—Z or —Y—O—CO—Z, independently represents an alkyl grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom and which may have a substituent, or abenzyl group.

Each of R⁶ to R¹⁰, R¹², R¹⁴ and R¹⁵, when these members are not—Y—CO—O—Z or —Y—O—CO—Z, independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom and which may have a substituent, a phenylgroup, a phenoxy group, an N-alkylcarbamoyl group or an N-alkylsulfamoylgroup.

R¹ to R¹⁵ may combine in the same compound to form a ring.

In the case where R¹ to R¹⁵ are an alkyl group having a carbon number of1 to 25, in which a part of carbon atoms may be substituted with aheteroatom and which may have a substituent, each of these members mayhave, as the substituent, another onium salt represented by any one offormulae (1) to (3). That is, the onium salt may be a compound where aplurality of compounds represented by any one of formulae (1) to (3) areconnected through R¹ to R¹⁵. At this time, the structures of theplurality of onium salts may be the same or different. This compoundspecifically includes a 1,2-ethanediaminium salt, a 4,4′-bipyridiniumsalt, etc.

In the case where each of R¹ to R¹⁵ is an alkyl group having a carbonnumber of 1 to 25, a part of carbon atoms in the structure thereof maybe substituted with a heteroatom. Specifically, the methylene group maybe substituted with a heteroatom-containing structure such as —O—, —S—,—SO—, —SO₂—, —NH—, —NR¹⁶⁻ (R¹⁶ represents a monovalent aliphatichydrocarbon group having a carbon number of 1 to 25 or a monovalentaromatic hydrocarbon group), —CONR¹⁷— (R¹⁷ represents a hydrogen atom, amonovalent aliphatic hydrocarbon group having a carbon number of 1 to 25or a monovalent aromatic hydrocarbon group), —NHCONH—, —CONHCO— and—SO₂NR¹⁷— (R¹⁷ has the same meaning as above).

Among others, each of R¹ of R⁵, R¹¹ and R¹³ is preferably a methylgroup, an ethyl group, a propyl group, an isopropyl group, a tert-butylgroup, an octyl group, an octadecyl group or a benzyl group, morepreferably a methyl group or an ethyl group.

Each of R⁶ o R¹⁰, R¹², R¹⁴ and R¹⁵ is preferably a hydrogen atom, achlorine atom, a methyl group, an ethyl group, a propyl group, anisopropyl group, a tert-butyl group, an octyl group, an octadecyl group,a halogen atom or a phenyl group, more preferably a hydrogen atom, atert-butyl group or a phenyl group.

X⁻ represents an anion species of the onium salt and is a monovalentanion. The anion species is specifically a hydrogen sulfate ion, amonomethyl sulfate ion, a halide ion, a nitrate ion, an acetate ion, ahydrogen carbonate ion, a dihydrogen phosphate ion, a sulfonate ion, acarboxylate ion or a hydroxide ion, and from the standpoint that theanion does not attach to the epoxy group or the carbon-carbon doublebond or the preparation is easy, a monomethyl sulfate ion, a hydrogensulfate ion, a chlorine ion, an acetate ion, a dihydrogen phosphate ionor a hydroxide ion is preferred.

Out of the compounds represented by formula (1), specific compounds thatcan be suitably used as the onium salt of the present invention includethe compounds represented by the following formulae (8) to (11), (34)and (35). Here, the compounds represented by the following formulae (8)to (10) are novel compounds suitable as the onium salt of the presentinvention.

These compounds are preferable in that the compound has a plurality ofester structures in the molecule and not only can be converted to awater-soluble compound after hydrolysis but also can be easilysynthesized from an easily available raw material, and among others, (8)to (11) are preferred in view of ease of instrumental analysis such ashigh-performance liquid chromatograph and ease of production control.

(in formulae (8) to (11), (34) and (35), R²⁰ represents a hydrogen atom,a halogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an alkoxycarbonyl group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group; each of R²¹ to R²³ independently represents analkyl group having a carbon number of 1 to 25, in which a part of carbonatoms may be substituted with a heteroatom, or a benzyl group; R²⁴represents an alkyl group having a carbon number of 1 to 25, in which apart of carbon atoms may be substituted with a heteroatom; R²⁰ to R²⁴may combine in the same compound to form a ring; k represents an integerof 1 to 4;

each of R³¹ and R³² independently represents a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom;

provided that a plurality of k, R²⁰ or R³¹ present in the same compoundmay be the same or different and the total number of carbon atomscontained in the cation moiety in the formula is 20 or more; and X⁻represents a monovalent anion).

As to the compound represented by formula (2), specific compounds thatcan be suitably used as the onium salt of the present invention includethe compounds represented by the following formulae (12) and (31). Here,the compounds represented by the following formulae (12) and (31) arenovel compounds suitable as the onium salt of the present invention.

(in formula (12), R²⁰ represents a hydrogen atom, a halogen atom, acyano group, a nitro group, an alkyl group having a carbon number of 1to 25, in which a part of carbon atoms may be substituted with aheteroatom, a phenyl group, a phenoxy group, a benzyl group, analkoxycarbonyl group, an N-alkylcarbamoyl group or an N-alkylsulfamoylgroup; R²⁰ may combine in the same compound to form a ring; k representsan integer of 1 to 4; provided that a plurality of k or R²⁰ present inthe same compound may be the same or different;

each of R³¹ and R³² independently represents a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom; the total number ofcarbon atoms contained in the cation moiety in the formula is 20 ormore; and X⁻ represents a monovalent anion).

(in formula (31), R²⁰ represents a hydrogen atom, a halogen atom, acyano group, a nitro group, an alkyl group having a carbon number of 1to 25, in which a part of carbon atoms may be substituted with aheteroatom, a phenyl group, a phenoxy group, a benzyl group, analkoxycarbonyl group, an N-alkylcarbamoyl group or an N-alkylsulfamoylgroup and may combine in the same compound to form a ring; k representsan integer of 1 to 4; provided that a plurality of R²⁰ present in thesame compound may be the same or different;

R³¹ represents a divalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom;

R³³ represents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25, which may have a substituent;

the total number of carbon atoms contained in the cation moiety in theformula is 20 or more; and X⁻ represents a monovalent anion).

In formulae (8) to (12), (31), (34) and (35), R²⁰ is preferably ahydrogen atom or an alkyl group having a carbon number of 1 to 4; eachof R²¹ to R²³ is preferably an alkyl group having a carbon number of 1to 18, more preferably an alkyl group having a carbon number of 1 to 8;R²⁴ is preferably an alkyl group having a carbon number of 1 to 8; eachof R³¹ and R³² is independently preferably an alkylene group having acarbon number of 1 to 11, more preferably an alkylene group having acarbon number of 1 to 5, still more preferably an ethylene group or anethylene group substituted with a propane-1,2-diyl group; R³¹ and R³²may combine to form a cyclic structure such as pyranose ring; R³³ ispreferably an alkyl group having a carbon number of 1 to 16; k ispreferably 1; and X⁻ is preferably a monomethyl sulfate ion, a hydrogensulfate ion, a dihydrogen phosphate ion or a chlorine ion.

One of the onium salts may be used alone, or two or more thereof may beused in appropriate combination.

The use amount of the onium salt based on the catalytic metal componentmay be appropriately adjusted according the properties of the substrateor the like used and is not particularly limited but is usually from 0.1to 10 times by mol, preferably from 0.3 to 5.0 times by mol, morepreferably from 0.2 to 2.0 times by mol, per one atom of the catalyticmetal component used.

<Synthesis Method of Onium Salt>

The above-described onium salts can be synthesized by alkylating therespective corresponding tertiary amines, pyridines, imidazoles, etc.The reagent employed for the alkylation is not particularly limited, butR¹⁸-A (wherein A represents a halogen atom such as chlorine, bromine andiodine, an aromatic sulfonyl such as p-toluenesulfonyl andmethanesulfonyl, an aliphatic sulfonyl, a sulfuric acid ester, acarbonic acid ester or an oxylanyl group, and R¹⁸ represents R¹ to R⁴,R⁵, R¹¹ or R¹³ in formulae (1) to (3) or a substituent convertible to R¹to R⁴, R⁵, R¹¹ or R¹³) is used.

Specific examples of R¹⁸-A include an alkyl halide compound such asmethyl iodide, ethyl iodide, ethyl bromide, octyl chloride and cetylchloride; a sulfonyl compound such as methanesulfonic acid octyl esterand p-toluenesulfonic acid benzyl ester; a sulfonic acid ester such asdimethyl sulfate and diethyl sulfate; a carbonic acid ester such asdimethyl carbonate and diethyl carbonate; and an oxylanyl compound suchas glycidol and epichlorohydrin.

The alkylation reaction may also use a base. Specific examples of thebase used include an inorganic base such as potassium carbonate, sodiumcarbonate, cesium carbonate, sodium hydrogen carbonate, potassiumhydrogen carbonate, sodium hydroxide and potassium hydroxide; and anorganic base such as ammonia, methylamine and ethylamine. Among these,potassium carbonate, sodium carbonate, sodium hydrogen carbonate,potassium hydrogen carbonate and potassium sulfate are preferred, andpotassium carbonate is more preferred.

The alkylation reaction may also use an organic solvent. The solventused for the reaction may be removed by distillation after the reactionor after the later-described post-reaction treatment, or the solutionafter the post treatment may be subjected as it is to the epoxidationreaction. Specific examples of the organic solvent used include esterssuch as ethyl acetate, aliphatic hydrocarbons such as heptane, hexaneand cyclohexane, aromatic hydrocarbons such as benzene, toluene, xyleneand pyridine, aprotic solvents such as acetonitrile, tetrahydrofuran,dioxane and 1,2-dimethoxyethane, ketones such as acetone and methylethyl ketone, aprotic polar solvents such as N,N′-dimethylformamide,N-methylpyrrolidone and dimethyl sulfoxide, an halogen-containingsolvents such as chloroform, dichloromethane, 1,2-dichloroethane andchlorobenzene. Among these, toluene, hexane and heptane are preferred,and toluene is more preferred.

After the completion of alkylation reaction, inorganic materialsproduced by the reaction may be appropriately removed by an appropriatesuch as filtration and washing.

In the case of performing the alkylation by using R¹⁸-A, the oniumproduced often forms a salt having A⁻ as the counter ion. Also, in thecase of performing a washing operation, the onium often form a salt witha hydroxide ion in water or an ion in the cleaning water. Such a counterion can be converted to a desired counter ion by an operation such aswashing or ion exchange resin treatment. For example, in the case ofperforming methylation by using dimethyl sulfate, a monomethyl sulfatesalt is formed, but this salt can be formed into hydrogen sulfate saltby the washing with aqueous sulfuric acid.

The method for introducing the substituent —Y—CO—O—Z or —Y—O—CO—Z (Y andZ have the same meanings as above) into the onium salt includes, forexample, the following methods:

1) a method of reacting A-Y—CO—O—Z or A-Y—O—CO—Z (A has the same meaningas above) with the above-described tertiary amines, pyridines orimidazoles as a raw material of the onium salt and thereby introducingthe ester group;

2) a method of esterifying amines, pyridines or imidazoles each having—Y—CO₂H to form —Y—CO—O—Z and alkylating the ester as above to give anonium salt;

a method of esterifying amines, pyridines or imidazoles each having—Y—OH to form —Y—O—CO—Z and alkylating the ester as above to give anonium salt; or a method of subjecting amines, pyridines or imidazoleseach having —Y—CO—O—R¹⁹ (R¹⁹ represents an alkyl group having a carbonnumber of 1 to 12) to a transesterification reaction to form —Y—CO—O—Zand alkylating the ester as above to give an onium salt;

3) a method of esterifying an onium salt containing —Y—CO₂H to form—Y—CO—O—Z;

a method of esterifying an onium salt containing —Y—OH to form—Y—O—CO—Z; or

a method of subjecting an onium salt containing —Y—CO—O—R¹⁹ to atransesterification reaction to form —Y—CO—O—Z; and

4) a method of alkylating amines, pyridines or imidazoles each having—Y—CO—O—Z or —Y—O—CO—Z to give an onium salt; or

a method using, as a raw material, an ammonium salt, a pyridinium saltor imidazolinium salt each having —Y—CO—O—Z or —Y—O—CO—Z.

Of these, the method for esterification to —Y—CO—O—H in 2) and 3)includes a method of effecting the halogenation to form —Y—CO—O-T (Trepresents a halogen atom) and then reacting with a correspondingalcohol Z—OH, a method of dehydrating and condensing Z—OH in thepresence of an acid catalyst or by using a condensing agent such as DDCand CDI, and a method of subjecting —Y—CO—O—R¹⁹ to a transesterificationreaction. The methods of effecting the dehydration/condensation andtransesterification include a method of reacting a corresponding alcoholZ—OH in the presence of an acid catalyst. On this occasion, it ispreferable to perform the transesterification reaction while removingthe produced water or R¹⁹—OH by distillation, adsorption or othermethods.

The method of esterifying —Y—OH includes a method of reacting thealcohol with a corresponding acid chloride Z—CO-T (T represents ahalogen atom), and a method of dehydrating and condensing Z—CO—O—H inthe presence of an acid catalyst or by using a condensing agent such asDCC and CDI. The method of subjecting —Y—CO—O—R¹⁹ to atransesterification reaction includes a method of reacting acorresponding alcohol Z—OH in the presence of an acid catalyst. On thisoccasion, it is preferable to perform the transesterification reactionwhile removing the produced water or R¹⁹—OH by distillation, adsorptionor other methods. Among these methods, in view of the cost, a method ofintroducing the ester group by performing dehydration/condensation ortransesterification in the presence of an acid catalyst is preferred inindustry.

Examples of the synthesis method 3) for an onium salt include a methodwhere a commercially available surfactant having a long-chainalkyl-di(hydroxyethyl)ammonium salt structure is esterified to give anonium salt.

At this time, as the acid catalyst used, for example, a mineral acidsuch as sulfuric acid, nitric acid and hydrochloric acid; an organicacid such as benzenesulfonic acid, p-toluenesulfonic acid,methanesulfonic acid, ethanesulfonic acid, trifluoromethanesulfonicacid, trichloromethanesulfonic acid, trifluoroacetic acid,trichloroacetic acid and acetic acid; a tungstic acid, a molybdic acidor a heteropolyphosphoric acid thereof, such as H₃PW₁₂O₄₀, H₄SiW₁₂O₄₀,H₄TiW₁₂O₄₀, H₅CoW₁₂O₄₀, H₅FeW₁₂O₄₀, H₆P₂W₁₈O₆₂, H₇PW₁₁O₃₃, H₄TiMo₁₂O₄₀,H₃PMo₁₂O₄₀, H₇PMo₁₁O₃₉, H₆P₂Mo₁₈O₆₂, H₄PMoW₁₁O₄₀, H₄PVMo₁₁O₄₀,H₄SiMo₁₂O₄₀, H₅PV₂Mo₁₀O₄₀, H₃PMo₆W₆O₄₀, H_(0.5)Cs_(2.5)PW₁₂O₄₀ andhydrates thereof; a cation-exchange resin such as Amberlyst IR120; andan H-type zeolite such as H—ZSM-5 can be used. Among these, sulfuricacid is preferred in view of the cost, but in the case where a sulfateis precipitated to reduce the reactivity, it is preferably to use anorganic acid such as p-toluenesulfonic acid and methanesulfonic acid, ifdesired. As for the use amount of such a catalyst, the catalyst may beused in an amount of 0.1 to 100 wt %, preferably from 1 to 20 wt %,based on the substrate.

Although not limited in particular, the solvent used is not especiallylimited as long as it does not participate in the reaction, and includesaromatic hydrocarbons such as benzene, toluene and xylene, and aliphatichydrocarbons such as hexane, heptane, octane and dodecane.

The amount of the solvent used is not particularly limited but if a saltof the substrate and the acid catalyst is precipitated from the system,the reaction rate may decrease. Therefore, it is preferable toappropriately adjust the amount according to the properties of thesubstrate or acid.

The onium salt obtained through the above-described process may be onceisolated, purified and then used for the epoxidation reaction or may beused without isolation and purification but is preferably used for theepoxidation reaction without isolation and purification, because this isadvantageous in view of production efficiency and also the onium saltcan be used for the reaction by suppressing its decomposition. In thecase where the “active hydrogen-containing functional group” is analkoxycarbonyl group or an acyloxy group, the composition may contain acarboxylic acid or an alcohol, which is a decomposition product of theonium salt.

<Phosphoric Acids and Phosphonic Acids>

The catalyst composition of the present invention may contain, and inview of reactivity, preferably contains, at least either phosphoricacids and phosphonic acids (excluding an onium salt). At least eitherphosphoric acids or phosphonic acids may be sufficient if it is presenttogether with the catalytic metal component and the onium salt at thetime of production and reaction of an epoxy compound, and may be mixedin the reaction system or may be previously mixed outside the reactionsystem.

Phosphoric acids specifically include, for example, an inorganicphosphoric acid such as phosphoric acid, polyphosphoric acid andpyrophosphoric acid; an inorganic phosphate such as sodium phosphate,potassium phosphate, ammonium phosphate, sodium hydrogenphosphate,potassium hydrogenphosphate, ammonium hydrogenphosphate, sodiumdihydrogenphosphate, potassium dihydrogenphosphate and calciumdihydrogenphosphate; and phosphoric acid esters such as monomethylphosphate, dimethyl phosphate, trimethyl phosphate, triethyl phosphateand triphenyl phosphate. Incidentally, in the case of phosphoric acidesters, this indicates phosphoric acid esters excluding an onium salthaving a phosphoric acid ester group as the “substituent convertible toan active hydrogen-containing functional group or a salt thereof”.

The phosphoric acids are preferably an inorganic phosphoric acid andpreferably phosphoric acid.

The phosphonic acids include an aminomethylphosphonic acid, aphenylphosphonic acid, etc.

Among these, inexpensive phosphoric acid is preferred.

The use amount of at least either phosphoric acids or phosphonic acidsis not particularly limited, and the proper use amount differs accordingto the kind of at least either phosphoric acids or phosphonic acids usedor the kind of the catalytic metal component. The use amount is adjustedsuch that the pH of the aqueous phase of the later-described reactionsystem falls in an appropriate range, but in general, the equivalent ofphosphorus contained in the at least either phosphoric acids orphosphonic acids is usually from 0.1 to 10 times by mol, preferably from0.2 to 5.0 times by mol, more preferably from 0.2 to 3.0 times by mol,per one atom of the metal in the catalytic metal component used.

<Reaction Solvent in Epoxidation Reaction>

The mode of the reaction for producing an epoxy compound from an olefincompound in the present invention (hereinafter, sometimes referred to as“epoxidation reaction of the present invention”) is not particularlylimited but is usually performed in a two-phase reaction system of anaqueous phase and an organic phase. Because, by performing the reactionin a two-phase reaction system, the epoxy compound produced by thereaction of the present invention swiftly dissolves in the organic phaseand as described later, the aqueous phase usually exhibits acidity,making it possible to prevent the epoxy ring of the produced epoxycompound from decomposition due to ring opening, rearrangement, etc.

The epoxidation reaction of the present invention may use a reactionsolvent, if desired. In the case where the olefin compound used for thereaction or the epoxy compound produced is liquid under the reactionconditions, the compound may be used for the reaction without using areaction solvent. Because, hydrogen peroxide usually contains water andby the mixing thereof, a two-phase reaction system can be formed. In thecase where the olefin compound is solid, a reaction solvent ispreferably used, and the compound may be dissolved or suspended in thesolvent but usually, is preferably dissolved in a reaction solvent underthe reaction temperature condition.

The reaction solvent used is not particularly limited as long as it doesnot participate in the reaction, and an organic solvent forming atwo-phase system with water is preferred. The organic solvent includesaromatic hydrocarbons such as benzene, toluene and xylene, aliphatichydrocarbons such as hexane, heptane, octane and dodecane, alcohols suchas methanol, ethanol, isopropanol, butanol, hexanol and cyclohexanol,halogen-based solvents such as chloroform, dichloromethane anddichloroethane, ethers such as tetrahydrofuran and dioxane, ketones suchas methyl ethyl ketone, methyl isobutyl ketone, cyclopentanone andanone, nitriles such as acetonitrile and butyronitrile, ester compoundssuch as ethyl acetate, butyl acetate and methyl formate, amides such asN,N′-dimethylformamide and N,N′-dimethylacetamide, ureas such asN,N′-dimethylimidazolidinone, and a mixture of such solvents, witharomatic hydrocarbons, aliphatic hydrocarbons, and a mixture of such asolvent being preferred. Furthermore, water and toluene, which arestable to the reaction and have a boiling point higher than the reactiontemperature, are more preferred.

In the case of using a reaction solvent, the use amount thereof differsdepending on the solubility of the compound, but since the reaction ratemay decrease as the amount of the reaction solvent increases, the useamount of the reaction solvent is usually from 0.1 times or more and 10times or less, preferably 5 times or less, more preferably 3 times orless, based on the olefin compound.

At the time of reaction, water may be further added. Hydrogen peroxideadded usually contains water and therefore, even when water is notadded, an aqueous phase is formed, but water may be added, if desired.In the case of adding water, the amount of water added is from 0.1 to 10times, preferably from 0.1 to 5 times, more preferably from 0.1 to 3times, based on the olefin compound.

In the present invention, the use amount of each of the catalytic metalcomponent, onium salt and at least either phosphoric acids or phosphonicacids is as described above, but the mole fraction of catalytic metalcomponent/onium salt is usually 0.2 or more, preferably 0.3 or more,more preferably 0.5 or more, and usually 4 or less, preferably 3 orless, more preferably 2 or less.

The mole fraction of catalytic metal component/(at least eitherphosphoric acids or phosphonic acids) is usually 0.2 or more, preferably0.3 or more, more preferably 0.5 or more, and usually 4 or less,preferably 3 or less, more preferably 2 or less.

At least either phosphoric acids or phosphonic acids is preferably addedsuch that the pH of the aqueous phase of the reaction solution falls ina proper range, but the pH is adjusted by adding an acid or a base, ifdesired.

The structure of the catalytic metal component such as tungsten acids inthe present invention changes according to its pH and changes in thereaction activity. Therefore, the pH is preferably adjustedappropriately depending on the reactivity of olefin compound, thestability of epoxy group, the distribution or solubility of the compoundto water, etc.

The pH of the aqueous phase of the reaction solution differs dependingon the stability of epoxy compound or the solubility in water but isusually 2 or more, preferably 2.5 or more, and usually 6 or less,preferably 5 or less.

In the case where the reaction solution is a two-phase system of anaqueous phase and an organic phase, when the pH of the aqueous phase isexcessively acidic, a ring-opening reaction or a rearrangement reactionof the epoxy group readily proceeds, and when the onium salt has analkoxycarbonyl group, an acyloxy group, etc., such a group is hydrolyzedand may arise a problem, for example, the reactivity is reduced. Also,when the pH of the aqueous phase is excessively basic, there may arise aproblem, for example, the reaction is extremely retarded, the hydrogenperoxide decomposes, or the alkoxycarbonyl group or acyloxy grouphydrolyses.

In order to adjust the pH of the aqueous phase of the reaction solution,an acid such as phosphoric acid, aminomethylphosphonic acid,phenylphosphonic acid, sulfuric acid, nitric acid, hydrochloric acid andperchloric acid; an inorganic base such as sodium hydroxide, potassiumhydroxide, sodium carbonate, potassium carbonate, sodium hydrogencarbonate, potassium hydrogen carbonate, phosphoric acid, disodiumhydrogenphosphate and dipotassium hydrogenphosphate, or an organic basesuch as ammonia, methylamine and ethylamine, may be added, if desired,

<Production Method of Epoxy Compound>

The production method of the present invention is specifically describedbelow.

<Raw Material>

The compound having a carbon-carbon double bond used as a raw materialin the present invention is not particularly limited as long as it is acompound having one or more carbon-carbon double bonds in the molecule,but the compound includes, for example, a compound represented by thefollowing formula (30):

(in formula (30), R represents an allyl group, the allyl group may besubstituted with an alkyl group, a phenyl group or an alkoxycarbonylgroup,

A²⁰¹ represents an (m201+1)-valent aromatic or aliphatic hydrocarbongroup that may have a substituent, A²⁰² represents a divalent aromaticor aliphatic hydrocarbon group that may have a substituent, and A²⁰³represents an (m203+2)-valent aromatic or aliphatic hydrocarbon groupthat may have a substituent, incidentally, in the following, the“aromatic or aliphatic hydrocarbon group” encompasses those having bothhydrocarbon skeletons, for example, a group having, in the molecule,both structures of an aromatic ring and an aliphatic ring,

each of X²⁰¹ and X²⁰² independently represents a direct bond or adivalent linking group that may have a substituent, p201 represents 0 or1,

each of m201 and m203 independently represents an integer of 1 or more,and n201 represents an integer of 1 or more, n202 represents 0 or aninteger of 1 or more, and n203 represents 0 or 1,

provided that in the case of n202=n203=0, when p201=0, A²⁰¹ becomesm201-valent and when p201=1, X²⁰¹ is a hydrogen atom or a monovalentgroup, and

provided that a plurality of R, A²⁰¹, A²⁰², X²⁰¹, X²⁰², m201 or p201contained in one molecule may be the same or different).

Among the compounds represented by formula (30), compounds representedby the following formulae (4) to (6) are preferred:

(A¹)-(OR)_(m1)  (4)

(in formula (4), R represents an allyl group, the allyl group may besubstituted with an alkyl group, a phenyl group or an alkoxycarbonylgroup, A¹ represents an m1-valent aromatic or aliphatic hydrocarbongroup, and m1 represents an integer of 1 or more, provided that aplurality of R contained in one molecule may be the same or different).

The aromatic hydrocarbon group represented by A¹ includes an m1-valentgroup obtained by removing m1 hydrogens from an aromatic hydrocarbonhaving a carbon number of 6 to 14, such as benzene ring, naphthalenering and anthracene ring, and is preferably a benzene ring having acarbon number of 6.

The aliphatic hydrocarbon group includes a group where the correspondinghydroxy group (that is, (A¹)-(OH)_(m1)) is a linear fatty acidpolyhydric alcohol such as diethylene glycol, propane-1,3-diol,butane-1,4-diol and polyvinyl alcohol; a linear polyhydric alcoholhaving a branched substituent, such as neopentyl glycol,2-methylpropanediol, 2,2-dimethylpropanediol and pentaerythritol; apolyhydric alcohol having an ether group in the molecular chain, such asdiethylene glycol, triethylene glycol and polytetramethylene glycol(PTMG); alicyclic diols such as carbonate polyol (e.g., ethanediolcarbonate, butanediol carbonate, ethanediol polycarbonate, butanediolpolycarbonate), cyclopentanediol, cyclopentanedimethanol,cyclopentanediethanol, cyclohexanediol, cyclohexanedimethanol,cyclohexanediethanol, norbomanediol, norbornanedimethanol,norbomanediethanol and adamantanediol; a polyhydric alcohol having anether group in the ring structure, such as erythritan, isosorbide and1,4-dioxane-2,5-dimethanol; sugars such as glycoside, mannitol andsorbitol, in which a part of hydroxyl groups may be protected; oralkanolamines such as triethanolamine; (that is, a structure obtained byremoving a hydroxyl group from these compounds).

The substituent other than the OR group, which may be substituted on thearomatic or aliphatic hydrocarbon group represented by A¹ includes analkyl group having a carbon number of 1 to 4, such as methyl group,ethyl group and propyl group; an alkyloxy group having a carbon numberof 1 to 4, such as methoxy group, ethoxy group and propyloxy group; anitro group; etc. In the case of having a substituent other than the ORgroup, the upper limit of the number thereof, that is, the upper limitof the number of substituents substitutable on the group represented byA¹, is usually 4 or less, preferably 3 or less, and usually 1 or more.

m1 represents an integer of 1 or more and is preferably an integer of 2or more, and the upper limit thereof is dependent on the number ofhydrogen atoms substitutable on the group represented by A¹ but isusually 4 or less, preferably 2.

Preferred examples of the compound represented by formula (4) includethose represented by any one of the formula group (7) below, and thecompound may have, on the benzene ring, a substituent other than the ORgroup, for example, a tert-butyl group. The compound may also be anuclear hydrogenated product where the aromatic ring is partially orwholly reduced. Furthermore, examples of the compound where A¹ is analiphatic hydrocarbon group include isosorbide,1,4-cyclohexanedimethanol, and 2,3-norbornane diol.

(in formula (5), R represents an allyl group, the allyl group may besubstituted with an alkyl group, a phenyl group or an alkoxycarbonylgroup, A²¹ represents an (m2+1)-valent aromatic or aliphatic hydrocarbongroup that may have a substituent, A²² represents a divalent aromatic oraliphatic hydrocarbon group that may have a substituent, thesubstituents A²¹ and A²² connected through X² or a plurality of adjacentsubstituents A²² may combine with each other to form a ring, X²represents a direct bond or a divalent linking group that may have asubstituent, m2 represents an integer of 1 or more, and n2 represents 0or an integer of 1 or more, provided that a plurality of R, A²¹, A²², X²or m2 contained in one molecule may be the same or different).

Each of A²¹ and A²² represents an (m1+2)-valent or divalent aromatic oraliphatic hydrocarbon group, and the hydrocarbon group may have asubstituent.

The aromatic or aliphatic hydrocarbon group represented by A²¹ and A²²includes a group derived from the same hydrocarbon as A¹ in formula (4),and the carbon number thereof is also the same. The substituent that maybe substituted on the group represented by A²¹ or A²² includes an alkylgroup having a carbon number of 1 to 4, such as methyl group, ethylgroup and propyl group; an alkyloxy group having a carbon number of 1 to4, such as methoxy group, ethoxy group and propyloxy group; a nitrogroup; etc., with an alkyl group being preferred.

In the case where each of A²¹ and A²² has a substituent other than thegroup specified in formula (5), the upper limit of the number thereof,which is the upper limit of the number of substituents substitutable onthe group represented by A²¹, is usually 4 or less, preferably 3 orless.

X² represents a direct bond or a divalent linking group that may have asubstituent, and the divalent linking group includes, for example, amethylene group, a dimethylmethylene group, a ditrifluoromethylmethylenegroup, an ethylene group, a propylene group, a 2,2-propylene group,—C(CH₃)═CH—, and an alicyclic hydrocarbon having a carbon number of 7 to10 and having a crosslinked and condensed ring structure where amethylene group, a cyclohexylene group, —CO—, —O—, —S—, —SO2-, —SO—,—COO—, —C═C—, —C—O—C—, —CH(CN)—, —N═CH—, tetrahydrodicyclopentadiene,etc. is substituted with a cyclic structure (e.g., phenyl group).Incidentally, the divalent linking group may have an optionalsubstituent. In the case where X² is an alkylene group, the alkylenegroup may have, as a substituent, an (RO)_(m2)-(A²¹) group (wherein R,A²¹ and m2 have the same meanings as in formula (5), and preferableranges are also the same). That is, the compound represented by formula(5) may further have an (RO)_(m2)-(A²¹)- group, other than two(RO)_(m2)-(A²¹)- groups specified in the formula.

Among others, X² is preferably a direct bond, a divalent alkylene grouphaving a carbon number of 1 to 4 (the alkylene group may be substitutedwith an aromatic hydrocarbon group, and the carbon number of thearomatic hydrocarbon group is preferably from 6 to 10), or an alicyclichydrocarbon having a carbon number of 7 to 10 and having a crosslinkedand condensed ring structure, more preferably a direct bond or analkylene group having a carbon number of 1 to 2 (the alkylene group maybe substituted with an aromatic hydrocarbon group, and the carbon numberof the aromatic hydrocarbon group is preferably from 6 o 8).

Furthermore, the adjacent substituents A²¹ and A²² connected through X²or a plurality of adjacent substituents A²² may combine with each otherto form a ring. Specifically, an example thereof is a case where A²¹ andA²² or two A²² combine through a methylene group or an ether group, andthe group includes a 5- or 6-membered hydrogen ring, an oxygenatom-containing 6-membered ring, etc.

m2 represents an integer of 1 or more, and the upper limit thereof isdependent on the number of hydrogen atoms substitutable on the grouprepresented by A²¹ but is usually 4 or less, preferably 2 or less.

n2 represents 0 or an integer of 1 or more, and the upper limit thereofis usually 5, preferably 2.

Among the compounds represented by formula (5), a compound representedby the following formula (5-1) is preferred:

(in formula (5-1), R¹⁰⁰ represents an allyl group that may have asubstituent, the substituent is an alkyl group having a carbon number of1 to 6, a phenyl group or an alkoxycarbonyl group having a carbon numberof 2 to 7,

A¹²¹ represents an {(m102)+1}-valent aromatic hydrocarbon group having acarbon number of 6 to 14, which may have a substituent, A¹²² representsa divalent aromatic hydrocarbon group having a carbon number of 6 to 14,which may be substituted, the substituents A¹²¹ and A¹²² connectedthrough X¹⁰² or a plurality of substituents A¹²² may combine with eachother to form a ring, X¹⁰² represents a direct bond, a methylene group,a dimethylmethylene group, a ditrifluoromethylmethylene group, anethylene group, —C(CH₃)═CH—, a methylene group that may be substitutedwith a phenyl group or (R¹⁰⁰)_(m2)-(A¹²¹)-, a cyclohexylene group, —CO—,—O—, —SO₂—, —COO—, —N═CH— or a tetrahydrodicyclopentadienylene group,provided that a plurality of R¹⁰⁰, A¹²¹, A¹²², X¹⁰² or m102 contained inone molecule may be the same or different, m102 represents an integer of1 to 4, and n102 represents an integer of 0 to 5).

In formula (5-1), among the substituents that may be substituted onR¹⁰⁰, a methyl group, a phenyl group, a methoxycarbonyl group and anethoxycarbonyl group are preferred, but R¹⁰⁰ is preferably anunsubstituted allyl group.

X¹⁰² is preferably a direct bond, a divalent alkylene group having acarbon number of 1 to 4 (the alkylene group may be substituted with anaromatic hydrocarbon group, and the carbon number of the aromatichydrocarbon group is preferably from 6 to 10), or an alicyclichydrocarbon having a carbon number of 7 to 10 and having a crosslinkedand condensed ring structure, more preferably a direct bond or analkylene group having a carbon number of 1 to 2 (the alkylene group maybe substituted with an aromatic hydrocarbon group, and the carbon numberof the aromatic hydrocarbon group is preferably from 6 o 8).

m102 is preferably 1 or 2, and n102 is preferably 0, 1 or 2.

Specific examples of the compound represented by formula (5) includecompounds represented by the following structural formulae (n representsan integer of 1 or more), and nuclear hydrogenated products thereofwhere the aromatic ring is partially or wholly reduced. Also, thesecompounds may have, on the benzene ring, a substituent other than the ORgroup and the methyl specified.

<Specific Examples of Compound Represented by Formula (5)>

(wherein R represents an allyl group, the allyl group may be substitutedwith an alkyl group, a phenyl group or an alkoxycarbonyl group, A³represents an (m3+2)-valent aromatic or aliphatic hydrocarbon group thatmay have a substituent, X³ represents a direct bond, an alkylene groupthat may have a substituent, or —R⁶¹-phenylene-R⁶²—, each of R⁶¹ and R⁶²independently represents an alkylene group, m3 represents an integer of1 or more, and n3 represents an integer of 2 or more, provided that aplurality of G, A³, X³ or m3 contained in one molecule may be the sameor different).

The aromatic or aliphatic hydrocarbon group represented by A³ includes agroup derived from the same hydrocarbon as A¹ in formula (4), and thecarbon number thereof is also the same.

X³ represents a direct bond, an alkylene group that may have asubstituent, or —R⁶¹-phenylene-R⁶²—, wherein each of R⁶¹ and R⁶²independently represents an alkylene group. The alkylene grouprepresented by X³, which may have a substituent, includes the samealkylene group as X² in formula (5), and among others, is preferably analkylene group having a carbon number of 1 to 4, preferably a carbonnumber of 1 or 2. Each of R⁶¹ and R⁶² in —R⁶¹-phenylene-R⁶²— isindependently an alkylene group having a carbon number of 1 to 4,preferably a carbon number of 1 or 2.

m3 represents an integer of 1 or more, and the upper limit thereof isdependent on the number of hydrogen atoms substitutable on the grouprepresented by A³ but is usually 4 or less, preferably 2 or less. n3represents an integer of 2 or more and is usually 20 or less, preferably10 or less.

Specific examples of the compound represented by formula (6) includecompounds represented by the following structural formulae (in theformulae, n and n′ have the same meaning as n3), and nuclearhydrogenated products thereof where the aromatic ring is partially orwholly reduced. Also, these compounds may have, on the benzene ring, asubstituent other than the —OR group and the methyl group specified.

<Specific Examples of Compound Represented by Formula (6)>

Another example of the compound having a carbon-carbon double bond,which is used as a raw material in the present invention, includes acyclic olefin compound represented by the following formula (36):

(in formula (36), each of i and j independently represents an integer of1 to 4, and each of R⁶⁴ to R⁷¹ independently represents a hydrogen atom,a halogen atom, an alkyl group that may have a substituent, an aromatichydrocarbon group that may have a substituent, a nitro group, an alkoxylgroup, a carbonyl group, an acyloxy group, or a carboxyl group or a saltthereof,

provided that out of R⁶⁴ to R⁷¹, any two or more members may combinewith each other to form a ring).

Each of R⁶⁴ to R⁷¹ independently represents a hydrogen atom, a halogenatom, an alkyl group that may have a substituent, an aromatichydrocarbon group that may have a substituent, a nitro group, an alkoxylgroup, a carbonyl group, an alkoxycarbonyl group, an acyloxy group, or acarboxyl group or a salt thereof.

The halogen atom includes, for example, a fluorine atom, a chlorineatom, and a bromine atom.

The alkyl group is preferably an alkyl group having a carbon number of 1to 20, and examples thereof include a linear or branched alkyl groupsuch as methyl group, ethyl group, n-propyl group, isopropyl group,n-butyl group, sec-butyl group, tert-butyl group, pentyl group, hexylgroup, heptyl group, octyl group, nonyl group, decyl group, cetyl groupand stearyl group; and a cycloalkyl group such as cyclobutyl group,cyclopentyl group, cyclohexyl group and cyclooctyl group. This alkylgroup may have a substituent, and the substituent includes, for example,a halogen atom such as fluorine atom, chlorine atom and bromine atom; analkoxyl group such as methoxy group, ethoxy group, propoxy group,isopropoxy group and butoxy group; a nitro group; a carboxyl group; analkoxycarbonyl group such as methoxycarbonyl group and ethoxycarbonylgroup; and an acyloxy group such as acetyloxy group and propionyloxygroup.

The aromatic hydrocarbon group includes, for example, a phenyl group anda naphthyl group.

The aromatic hydrocarbon group may have a substituent, and thesubstituent includes, for example, a halogen atom such as fluorine atom,chlorine atom and bromine atom; an alkoxyl group such as methoxy group,ethoxy group, propoxy group, isopropoxy group and butoxy group; a nitrogroup; a carboxyl group; an alkoxycarbonyl group such as methoxycarbonylgroup and ethoxycarbonyl group; an acyl group such as acetyl group,propionyl group and benzoyl group; and an acyloxy group such asacetyloxy group and propionyloxy group.

The alkoxyl group includes, for example, a methoxy group, an ethoxygroup, a propoxy group, an isopropoxy group, and a butoxy group.

The acyloxy group includes, for example, an acetyloxy group, apropionyloxy group, and a benzoyloxy group.

The salt of a carboxyl group includes, for example, an alkali metal saltsuch as sodium salt and potassium salt.

Incidentally, out of R⁶⁴ to R⁷¹, any two or more members may combinewith each other to form a ring.

Each of i and j independently represents an integer of 1 to 4,preferably from 1 to 3, more preferably 1 or 2, and most preferably 2.

The cyclic olefin represented by formula (36) includes, for example,cyclic non-conjugated olefins such as 1,4-cyclohexadiene,1,5-cyclooctadiene, 1,5,9-cyclododecatriene,1,5-dimethyl-1,5-cyclooctadiene, dicyclopentadiene and2,5-norbornadiene.

The compound further includes, for example, a styrene compoundrepresented by the following formula (37):

(in formula (37), each of R⁷² to R⁷⁶ independently represents a hydrogenatom, a linear or branched alkyl group having a carbon number of 1 to 8,an alkoxy group having a carbon number of 1 to 8, a cycloalkyl grouphaving a carbon number of 3 to 7, an aromatic hydrocarbon group, anaralkyl group, an acyl group, a hydroxy group, a halogen atom, acarboxyl group or an acyloxy group, and

each of R⁷⁷ and R⁷⁸ independently represents a hydrogen atom, a linearor branched alkyl group having a carbon number of 1 to 8, an alkoxygroup having a carbon number of 1 to 8, an alkoxycarbonyl group having acarbon number of 2 to 8, a cycloalkyl group having a carbon number of 3to 7, an aromatic hydrocarbon group, an aralkyl group, an acyl group, acarboxyl group or an acyloxy group,

provided that any two or more members out of R⁷² to R⁷⁸ may combine witheach other to form a ring).

Specific examples of the styrenes represented by formula (37) includestyrene, 4-methylstyrene, 4-fluorostyrene, 2,4-difluorostyrene,3-chlorostyrene, 4-chlorostyrene, 4-bromostyrene, 4-nitrostyrene,4-vinylbenzoic acid, α-methylstyrene, β-methylstyrene,1-phenyl-1-cyclohexene, indene, and dihydronaphthalene.

The olefin compound for use in the present invention may be subjectedto, if desired, a pretreatment such as removal of impurities when usingthe compound for the epoxidation reaction of the present invention.

The epoxidation reaction using hydrogen peroxide is sometimes affectedby a foreign material coming from the raw material, the solvent, thereaction vessel, the incidental equipment such as pipe and feed pump,etc., for example, a metal, activated carbon, silica gel or glass piece.The oxide of hydrogen oxide, etc. may decompose upon contact with theforeign material above to generate heat of reaction or oxygen andinvolve a danger. It is preferable to keep the reaction solution frommixing or effect of such a foreign material. Specifically, in order toremove those foreign materials, it is preferred that the olefin compoundis filtered, the olefin compound is washed with an acidic aqueoussolution, the olefin compound is washed with a chelating agent (acompound capable of forming a chelate with a metal; specifically, ametal masking agent), or the reaction is performed by allowing achelating agent to exist together at the time of epoxidation reaction.

The acid employed in the acidic aqueous solution for washing the olefincompound used as the raw material is not particularly limited in itskind but, specifically, includes an inorganic acid such as hydrochloricacid, sulfuric acid, nitric acid and phosphoric acid; and an inorganicacid such as acetic acid and citric acid.

The pH of the acidic aqueous solution is not particularly limited anddiffers according to the stability of the olefin compound used, but thewashing is performed at a pH of usually 1 or more, preferably 3 or more,and usually 5 or less, preferably 4 or less. Various salts may be addedfor the purpose of adjusting the pH, for example, sodium sulfate, sodiumacetate, sodium phosphate, disodium hydrogenphosphate, or sodium citratemay be added.

Specifically, a mixed aqueous solution of acetic acid and sodium sulfateis preferred. For example, an aqueous solution containing 4% acetic acidand 1% sulfuric acid and having a pH of about 4 is more preferred. Byperforming the washing treatment above, the metal is solubilized inwater and removed together with the aqueous phase.

The aqueous solution containing a chelating agent is not particularlylimited as long as it is an aqueous solution containing a compoundhaving a metal chelating ability, but an aqueous solution containing aso-called metal masking agent is preferred. The metal masking agentincludes, for example, ethylenediaminetetraacetic acid, pyrophosphoricacid, etc. described in JP-T-2002-501005. A method of washing thecompound with water containing at least eitherethylenediaminetetraacetic acid or pyrophosphoric acid is preferred. Byperforming this treatment, the metal is solubilized in water and removedtogether with the aqueous phase.

Also, the chelating agent may be used by adding it to the reactionsystem, and a method of adding at least eitherethylenediaminetetraacetic acid or pyrophosphoric acid to the reactionsolution is preferred. Because, the chelating agent as the metal maskingagent chelates metals, whereby decomposition of peroxide can besuppressed.

<Reaction Operation>

The specific method for the reaction operation in the production methodof the present invention is not particularly limited, but hydrogenperoxide, at least either a tungsten compound or a molybdenum compound,an onium salt, and if desired, at least either phosphoric acids orphosphonic acids are added to the olefin compound, and if desired, theabove-described organic solvent and a buffer solution are added.

The additions and mixing order of respective components are notparticularly limited as long as the reaction is not inhibited, but heatgeneration is involved at the time of epoxidation reaction anddecomposition of hydrogen peroxide and therefore, from the standpoint ofcontrolling the reaction progress or heat generation, a method wherehydrogen oxide is gradually added after adding respective components orwhere hydrogen peroxide in an amount necessary to oxidize at leasteither a tungsten compound or a molybdenum compound is previously addedto form at least either a tungsten peroxide or a molybdenum peroxide andthen the remaining hydrogen peroxide is gradually added, is preferred.The method for adding hydrogen peroxide may be addition in parts or maybe continuous and gradual addition. From a safety aspect, the hydrogenperoxide is preferably added additionally according to the progress ofreaction so as to prevent unreacted hydrogen peroxide from residing inthe reaction system.

<Reaction Conditions>

The reaction temperature in the production method of the presentinvention is not particularly limited as long as the reaction is notinhibited, but the reaction temperature is usually 10° C. or more,preferably 35° C. or more, more preferably 60° C. or more, and usually90° C. or less, preferably 80° C. or less, more preferably 75° C. orless. Because, if the reaction temperature is less than the lower limitabove, the reaction rate may be reduced, whereas if the reactiontemperature exceeds the upper limit above, this may be not preferredfrom a safety aspect.

The reaction time can be appropriately selected according to, forexample, the reaction temperature, the amount of catalyst, or the kindof raw material and is not particularly limited but is usually 1 hour ormore, preferably 3 hours or more, more preferably 4 hours or more, andusually 48 hours or less, preferably 36 hours or less, more preferably24 hours or less.

From a safety aspect, the reaction in the production method of thepresent invention is preferably performed under atmospheric pressure ina nitrogen stream.

Although this is not particularly limited, the production method of thepresent invention is usually performed in a two-phase reaction system ofan aqueous phase and an organic phase.

The appropriate pH during the reaction depends on the structure of thereaction raw material. For example, a cyclic olefin is easilyepoxidized, but the epoxy produced tends to undergo transition orcleavage, and therefore, a reaction under nearly neutral conditions ispreferred. On the other hand, an allyloxy ether is hardly epoxidized ascompared with a cyclic olefin and is less likely to undergo cleavage andfor this reason, there is a tendency that acidic conditions more than inthe case of a cyclic olefin are preferred. The pH is not particularlylimited, but the pH of the aqueous phase is usually 2 or more,preferably 2.5 or more, and usually 6 or less. At the time of reaction,the pH varies depending on the amount of hydrogen peroxide in theaqueous phase, or the produced epoxy is cleaved under acidic conditionsin the latter half of the reaction. Therefore, it is preferable toappropriately add an acid or a base according to the progress of thereaction and thereby keep the pH in an optimal range.

In the production method of the present invention, a buffer solution canalso be used. As for the kind of the buffer solution, a buffer solutionaccording to the objective pH may be appropriately used, as long as itdoes not inhibit the reaction. Examples of the buffer solution includean aqueous phosphate solution and as the combination of a hydrogenphosphate salt, a dihydrogen phosphate salt or a phenylphosphoric acid,include citric acid/sodium citrate, and acetic acid/sodium acetate.Depending on the case, the buffer solution may be formed by thecombination with the above-described tungstic acids.

In the production method of the present invention, a co-oxidant may alsobe used for the purpose of allowing the smooth progress of the reaction.Specifically, a carboxylic acid, preferably an aliphatic carboxylic acidhaving a carbon number of 1 to 10, may be incorporated into the catalystcomposition. The co-oxidant may be added to the composition or, forexample, in the case of an onium salt having an ester group, theco-oxidant may be generated by hydrolysis of the ester group.

In addition, similarly, a surfactant or a nitrogen-containing compoundsuch as amines and pyridine ring compound may be incorporated into theoxidant composition.

<Substrate Removal Step: After-Treatment Step>

In the production method of the present invention, an after-treatment isperformed after the completion of epoxidation reaction to convert thesubstituent contained in the onium salt to an active hydrogen-containingfunctional group or a salt thereof. The onium salt after conversion ofthe substituent transfers from the organic phase to the aqueous phase inthe reaction system and therefore, can be easily separated from theepoxy compound present in the organic phase. The epoxy compound as theproduct may be, if desired, further purified.

The method for converting the substituent contained in the onium salt toan active hydrogen-containing functional group or a salt thereof is notlimited as long as the object of the present invention is not impaired,but the method includes, for example, a method of converting thesubstituent by adding an acidic aqueous solution or a basic aqueoussolution to an extent not decomposing the epoxy compound, a method ofconverting the substituent by catalytic hydrogenation, a method ofconverting the substituent by heating, a method of converting thesubstituent by using an auxiliary agent or enzyme capable of selectivelyconverting the substituent, a method of converting the substituent byphotoreaction, and a method of converting the substituent by microwaveirradiation.

After the conversion to an active hydrogen-containing functional groupor a salt thereof, the onium salt transfers into water in the reactionsystem and as the method for separating the onium salt from the epoxycompound, a separation method according to the physical properties ofthe onium salt, not involving decomposition of the epoxy compound, isemployed. The separation method includes, for example, liquidseparation, washing, suspension-washing, adsorption, filtration, anddistillation.

This is specifically described below by referring to, for example, thecase of using an onium salt having an alkoxycarbonyl group or an acyloxygroup.

After the completion of epoxidation reaction, the aqueous phase issubjected to disposal, water washing and, if desired, addition of areductant for performing a quenching treatment of excessive hydrogenperoxide. The reductant is not particularly limited but includes sodiumsulfite, sodium thiosulfate, hydrazine, oxalic acid, etc. Also, thequenching treatment of excessive hydrogen peroxide by the addition of areductant may be performed after a treatment of converting the oniumsalt above to a water-soluble salt.

Subsequently, a treatment of converting the onium salt to awater-soluble salt is performed. Specifically, the treatment ispreferably for hydrolysis of the ester group contained in thealkoxycarbonyl group or acyloxy group. The method for hydrolysis is notparticularly limited but usually, a method using a basic compound isemployed. The basic compound specifically includes a metal hydroxidesuch as sodium hydroxide, potassium hydroxide, magnesium hydroxide andcalcium hydroxide, a metal carbonate such as sodium carbonate andpotassium carbonate, a phosphate such as sodium phosphate and sodiumhydrogenphosphate, and a basic solid such as alumina. For the reasonthat the operation is simple and easy, hydrolysis by a basic aqueoussolution is preferred, and this hydrolysis specifically includeshydrolysis by an aqueous sodium hydroxide solution or an aqueouspotassium hydroxide solution. Incidentally, in the case where thehydrolyzed compound of the onium salt has a property as a surfactant,the base treatment operation is preferably performed after distillingoff or while distilling off the reaction solvent, because thehydrolysate of the onium salt can be easily separated from the product.

The concentration, pH and temperature of the basic aqueous solution arenot particularly limited but can be selected in the range where theepoxy compound is not decomposed. Specifically, as for the concentrationof the aqueous solution, a basic aqueous solution with a normality of0.1 to 5N, preferably from 0.3 to 3N, more preferably from 0.5 to 2N, isused. The pH of the aqueous solution is usually from 10 to 12. As forthe temperature of the aqueous solution, the treatment is performedusually at 0° C. or more, preferably at 20° C. or more, and usually at60° C. or less, preferably at 45° C. or less. After the hydrolysis ofthe ester group, the resulting water-soluble onium salt is removed bywashing. In association therewith, the catalytic metal component is alsoremoved by the washing.

In the thus-obtained epoxy compound, the contents of the metal derivedfrom the catalytic metal component, for example, tungsten, and the oniumsalt are small. Also, although this may vary according to the chlorinecontent of the compound used for the reaction, the epoxy compound isgenerally characterized in that the chlorine content is small comparedwith an epoxy compound synthesized using epichlorohydrin.

<Purification>

The epoxy compound obtained by the method above may be, if desired,further purified. The specific purification method is not particularlylimited, and a known method may be appropriately used. In the case wherethe epoxy compound is a solid, the purification method includescrystallization, suspension-washing, liquid separation, adsorption,etc., and in the case where the epoxy compound is a liquid, thepurification method includes liquid separation, washing, adsorption, anddistillation.

The purification by liquid separation or washing includes a case ofcombining water and an organic solvent insoluble or sparingly soluble inwater, and a case of combining a plurality of organic solvents incapableof intermixing with each other. The combination of water and an organicsolvent insoluble or sparingly soluble in water includes, for example, acombination of water with an organic solvent such as ethyl acetate,toluene, diethyl ether, diisopropyl ether and n-hexane.

The combination of a plurality of organic solvents incapable ofintermixing with each other includes, for example, a combination ofN,N′-dimethylformamide and at least one member out of n-heptane,n-hexane, n-pentane, diisopropyl ether and xylene, a combination ofdimethylsulfoxide and at least one member out of n-heptane, n-hexane,n-pentane, diisopropyl ether, diethyl ether and xylene, a combination ofacetonitrile and at least one member out of n-heptane, n-hexane,n-pentane, cyclohexane and cyclopentane, and a combination of methanoland at least one member out of n-heptane, n-hexane and n-pentane.

The purification by crystallization may be performed by any of, forexample, a method of crystallizing the epoxy compound by cooling whiledistilling off the solvent under reduced pressure or without distillingoff the solvent, a method of precipitating the epoxy compound by addinga so-called poor solvent, a method of precipitating the epoxy compoundby combining a solvent allowing for high solubility of the compound, aso-called good solvent, and a poor solvent, and a solvent ofcrystallizing the epoxy compound by adding water after the completion ofreaction. The solvent may be any of an organic solvent, water, a mixturethereof, a combination of organic solvents, and the like, and a bettersolvent is selected according to the solubility of the compound. Theorganic solvent includes esters such as ethyl acetate, aliphatichydrocarbons such as heptane, hexane and cyclohexane, aromatichydrocarbons such as benzene, toluene and xylene, aprotic solvents suchas acetonitrile, tetrahydrofuran, dioxane and 1,2-dimethoxyethane,alcohols such as methanol, ethanol, 2-propanol and n-butanol, ketonessuch as acetone and methyl ethyl ketone, and aprotic polar solvents suchas N,N′-dimethylformamide, N-methylpyrrolidone and dimethylsulfoxide.

The purification by suspension-washing uses a solvent allowing for lowsolubility of the compound, a so-called poor solvent. The preferablepoor solvent differs depending on the compound but includes a solventhaving high polarity, e.g., alcohols such as methanol, and conversely,an aliphatic hydrocarbon having low polarity, such as butane, hexane andcyclohexane.

The water-soluble solvent includes tetrahydrofuran, 1,3-dioxolane,N,N,N-dimethylformamide, dimethylsulfoxide, etc., and such a solvent canbe used by mixing it with water. If the amount of the solvent is toosmall, the purification effect is insufficient, and if the amount of thesolvent is too large, this leads to reduction in the recoverypercentage. After the completion of suspension-washing, the solidmaterial is recovered by filtration and dried, whereby the targetcompound can be obtained.

In the purification by adsorption, chlorine-containing impurities areremoved, and the adsorbent includes activated carbon, activated earth,molecular sieve, activated alumina, zeolite, ion exchange resin, etc.

Among these purification methods, in view of the operation, a liquidseparation method is preferred irrespective of the condition of theepoxy compound. In the case where the epoxy compound is a solid, acrystallization method is effective.

<Epoxy Composition>

The epoxy compound is obtained through the above-described epoxidationreaction, the step of separating/removing the catalytic metal component,onium salt, etc., and, if desired, the purification step.

The epoxy composition obtained by the production method of the presentinvention is obtained as a composition having an extremely reducedcontent of a metal derived from the catalytic metal, and the content ofthe metal is usually 200 ppm or less, preferably 100 ppm or less, morepreferably 10 ppm or less, still more preferably 1 ppm or less.

Similarly, in the epoxy composition obtained by the production method ofthe present invention, the nitrogen content derived from the onium saltis small, and the content is usually 500 ppm or less, preferably 200 ppmor less, more preferably 10 ppm or less.

In the epoxy composition obtained by the production method of thepresent invention, the content of a halogen atom is small, and thecontent is usually 200 ppm or less, preferably 50 ppm or less, morepreferably 10 ppm or less. The production method of the presentinvention can be used for the production of the later-described epoxyresin and in addition, for the production of a medical intermediate,etc. having an epoxy structure. Also, the epoxy composition of thepresent invention can be used as the later-described epoxy resin and inaddition, as a medical intermediate, etc. having an epoxy structure. Theintermediate includes, for example, an antifungal or antidiabeticintermediate having a halogen-substituted styrene oxide structure. Theepoxy composition obtained by the method of the present invention has asmall impurity content and therefore, is relieved of the fear oftoxicity attributable to impurities.

The epoxy compound in the present invention (hereinafter, sometimesreferred to as the epoxy compound α) is not particularly limited as longas it is a compound having one or more epoxy groups in the molecule, butthe specific epoxy compound includes a compound represented by thefollowing formula (32):

(in formula (32), G represents a glycidyl group (2,3-epoxypropanylgroup), and the glycidyl group may be substituted with an alkyl group, aphenyl group or an alkoxycarbonyl group;

A²⁰¹ represents an (m201+1)-valent aromatic or aliphatic hydrocarbongroup that may have a substituent, A²⁰² represents a divalent aromaticor aliphatic hydrocarbon group that may have a substituent, and A²⁰³represents an (m203+2)-valent aromatic or aliphatic hydrocarbon groupthat may have a substituent;

each of X²⁰¹ and X²⁰² independently represents a direct bond or adivalent linking group that may have a substituent;

p201 represents 0 or 1;

each of m201 and m203 independently represents an integer of 1 or more;

n201 represents an integer of 1 or more, n202 represents 0 or an integerof 1 or more, and n203 represents 0 or 1;

provided that in the case of n202=n203=0, when p201=0, A²⁰¹ becomesm201-valent and when p201=1, X²⁰¹ is a hydrogen atom or a monovalentgroup; and

provided that a plurality of G; A²⁰¹, A²⁰², X²⁰¹, X²⁰², m201 or p201contained in one molecule may be the same or different).

In formula (32), G represents a glycidyl group (2,3-epoxypropanylgroup). The glycidyl group may be substituted with an alkyl group, aphenyl group or an alkoxycarbonyl group, and of these substituents, amethyl group, a phenyl group, a methoxycarbonyl group and anethoxycarbonyl group are preferred. In particular, G is preferably anunsubstituted glycidyl group.

Incidentally, A²⁰¹ to A²⁰³, X²⁰¹, X²⁰², n201 to n203, m201, m203 andp201 in formula (32) have the same meanings as in formula (30), andpreferable ranges are also the same.

Among the compounds represented by formula (32), the compoundsrepresented by the following formulae (13) to (15) are preferred.

(A¹)-(OG)_(m1)  (13)

(in formula (13), G represents a glycidyl group (2,3-epoxypropanylgroup), and the glycidyl group may be substituted with an alkyl group, aphenyl group or an alkoxycarbonyl group; A¹ represents an m1-valentaromatic or aliphatic hydrocarbon group that may have a substituent; andm1 represents an integer of 1 or more, provided that a plurality of Gcontained in one molecule may be the same or different).

Here, specific examples and preferable range of G are the same as thosein formula (32), and specific examples and preferable range of A¹ arethe same as those in formula (4).

(GO)_(m2)-(A²¹)-[X²-(A²²)]_(n2)—X²-(A²¹)-(OG)_(m2)  (14)

(in formula (14), G represents a glycidyl group, and the glycidyl groupmay be substituted with an alkyl group, a phenyl group or analkoxycarbonyl group; A²¹ represents an (m2+1)-valent aromatic oraliphatic hydrocarbon group that may have a substituent; A²² representsa divalent aromatic or aliphatic hydrocarbon group that may have asubstituent; the substituents A²¹ and A²² connected through X² or aplurality of adjacent substituents A²² may combine with each other toform a ring; X² represents a direct bond or a divalent linking groupthat may have a substituent; m2 represents an integer of 1 or more; andn2 represents 0 or an integer of 1 or more; provided that a plurality ofG, A²¹, A²², X² or m2 contained in one molecule may be same ordifferent).

Here, specific examples and preferable range of G are the same as thosein formula (32), and specific examples and preferable ranges of A²¹,A²², X², m2 and n2 are the same as those in formula (5).

H—[(A³(OG)_(m3)-X³]_(n3)—H  (15)

(in formula (15), G represents a glycidyl group, and the glycidyl groupmay be substituted with an alkyl group, a phenyl group or analkoxycarbonyl group; A³ represents an (m3+2)-valent aromatic oraliphatic hydrocarbon group that may have a substituent; X³ represents adirect bond, an alkylene group that may have a substituent, or—R⁶¹-phenylene-R⁶²-, wherein each of R⁶¹ and R⁶² independentlyrepresents an alkylene group; m3 represents an integer of 1 or more; andn3 represents an integer of 2 or more; provided that a plurality of G,A³, X³ or m3 contained in one molecule may be same or different).

Here, specific examples and preferable range of G are the same as thosein formula (32), and specific examples and preferable ranges of A³, X³,m3 and n3 are the same as those in formula (6).

The epoxy compound α obtained by the production method of the presentinvention is usually obtained as a composition containing a compound βhaving a structure where one or more glycidyl groups contained in theepoxy compound α are substituted with a 3-acyloxy-2-hydroxypropyl group(wherein the acyl group is a group represented by —CO—R³⁵ or —CO—Z).

These compounds are produced by the reaction of an onium salt and anepoxy compound under base conditions, which occurs mainly at the time ofafter-treatment step after the reaction.

Z represents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25, which may have a substituent.

R³⁵ represents a group represented by any one of the following (18) to(20):

(in formula (18),

R⁴¹ represents a direct bond or a divalent aliphatic hydrocarbon grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom, and each of R⁴² to R⁴⁴ independentlyrepresents an alkyl group having a carbon number of 1 to 25, in which apart of carbon atoms may be substituted with a heteroatom, or a benzylgroup;

in formula (19),

any one of R⁴⁵ to R⁵⁰ represents a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom,

provided that in the case where R⁴⁵ is a direct bond or a divalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, each of R⁴⁶to R⁵⁰ independently represents a hydrogen atom, a halogen atom, a cyanogroup, a nitro group, an alkyl group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom, aphenyl group, a phenoxy group, a benzyl group, an N-alkylcarbamoyl groupor an N-alkylsulfamoyl group, and

in the case where any one of R⁴⁶ to R⁵⁰ is a direct bond or a divalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, each ofother four members independently represents a hydrogen atom, a halogenatom, a cyano group, a nitro group, an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, a phenyl group, a phenoxy group, a benzyl group, anN-alkylcarbamoyl group or an N-alkylsulfamoyl group, and R⁴⁵ representsan alkyl group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom, or a benzyl group;and

in formula (20),

any one of R⁵¹ to R⁵⁵ represents a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom,

provided that in the case where either one of R⁵¹ and R⁵³ is a directbond or a divalent aliphatic hydrocarbon group having a carbon number of1 to 25, in which a part of carbon atoms may be substituted with aheteroatom, the other represents an alkyl group having a carbon numberof 1 to 25, in which a part of carbon atoms may be substituted with aheteroatom, or a benzyl group, and each of R⁵², R⁵⁴ and R⁵⁵independently represents a hydrogen atom, a halogen atom, a cyano group,a nitro group, an alkyl group having a carbon number of 1 to 25, inwhich a part of carbon atoms may be substituted with a heteroatom, aphenyl group, a phenoxy group, a benzyl group, an N-alkylcarbamoyl groupor an N-alkylsulfamoyl group, and

in the case where any one of R⁵², R⁵⁴ and R⁵⁵ is a direct bond or adivalent aliphatic hydrocarbon group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom,each of other two members independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an N-alkylcarbamoyl group or an N-alkylsulfamoyl group, and eachof R⁵¹ and R⁵³ independently represents an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a benzyl group;

the total number of carbon atoms contained in R⁴¹ to R⁴⁴ in formula (18)is 20 or more, the total number of carbon atoms contained in R⁴⁵ to R⁵⁰in formula (19) is 15 or more, and the total number of carbon atomscontained in R⁵¹ to R⁵⁵ in formula (20) is 17 or more; and

R⁴¹ to R⁵⁵ may combine in the same compound to form a ring).

Incidentally, the groups represented by formulae (18) to (20) correspondto the onium moiety of the onium salts represented by formulae (1) to(3).

That is, out of R⁴² to R⁵⁵ in formulae (18) to (20), R^(x) (x representsany one of 42 to 55) not bonded to —CO— of —CO—R³⁵ has the same meaning,out of R¹ to R¹⁵ in formulae (1) to (3), as the group except for—Y—CO—O—Z or —Y—O—CO—Z, and preferable groups are also the same.

On the other hand, out of R⁴² to R⁵⁵ in formulae (18) to (20), R^(y) (yrepresents any one of 42 to 55) and R⁴¹ bonded to —CO— of —CO—R³⁵ havethe same meaning as —Y— in formulae (1) to (3), and preferable groupsare also the same.

The compound β includes a compound where in formula (13) to (15) or(32), one or more -OG groups are substituted with a group represented bythe following formula (16) or (17) and one or more -OG groups may besubstituted with a group represented by the following formula (33):

(in formula (16), R³⁵ represents a group represented by any one offormulae (18) to (20); and in formula (17), Z represents a monovalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, or amonovalent aromatic hydrocarbon group having a carbon number of 4 to 25,which may have a substituent).

Here, Z has the same meaning as Z in formulae (1) to (3).

The epoxy composition of the present invention includes, for example, acomposition containing an epoxy compound α represented by the followingstructural formula (21) (hereinafter, sometimes referred to as “compound(21)”):

and a compound β represented by the following formula (22) (hereinafter,sometimes referred to as “compound (22)”) or a compound γ represented bythe following formula (23) (hereinafter, sometimes referred to as“compound (23)”):

In formula (22), Q represents R³⁵ or —Z in formula (16) or (17).Incidentally, the compound β may be a compound where the glycidyl ethergroup of the compound represented by formula (22) is substituted with agroup represented by formula (33). Furthermore, the epoxy compositionmay contain a compound where either one or both of glycidyl ether groupsof a compound represented by structural formula (21) are ring-opened andchanged to a group represented by formula (33).

The amount of the compound β (ester form) produced differs depending onthe compound structure, reaction conditions and after-treatmentconditions but is usually 0.05 mol % or more, and 10 mol % or less,preferably 5 mol % or less, based on the compound α.

The amount of the compound γ (diol form) produced differs depending onthe compound structure, reaction conditions and after-treatmentconditions but is usually 0.05 mol % or more, and 10 mol % or less,based on the compound α.

The content of such a compound may be reduced in the above-describedafter-treatment or purification step, but a small amount of the compoundremains in the epoxy compound α.

If the amount produced is smaller than the lower limit above, theadhesiveness of an epoxy resin obtained from the epoxy composition maybe reduced, whereas if the amount produced exceeds the upper limitabove, the number of reaction points at the time of polymerization ofthe epoxy composition is small, which may lead to reduction in theproductivity of an epoxy resin.

In the present invention, the abundance ratio of the compound β to thecompound α may be determined by NMR.

Specifically, the abundance ratio can be determined by comparing theintegrated value of proton peaks that are easy to specify and integrate,with the integrated value of peaks of the epoxy compound α. For example,in the case of the ester compound β, the abundance ratio can bedetermined by comparing the integrated value of proton peaks derivedfrom an alcohol or carboxylic acid forming the ester, with theintegrated value of peaks of the epoxy compound α.

Also, the abundance ratio of the compound γ to the compound α can bedetermined by LC (liquid chromatograph).

Specifically, the LC area ratio of the compound α and the compound γdetermined by LC analysis is corrected by taking into account thedifference factor between the compound α and the compound γ, that is,the difference in the UV absorption amount, and is thereby converted toa weight ratio or a molar ratio, and the abundance ratio can bedetermined therefrom.

Incidentally, when the LC analysis is not easy for the reason that exactmeasurement is difficult because of weak UV absorption of the compound αor compound γ or exact measurement at the same UV wavelength isdifficult, the area ratio may be determined by GC (gas chromatograph)analysis. Specifically, the GC area ratio of the compound α and thecompound γ determined by GC analysis is corrected by taking into accountthe difference in the factor of the compound α and the compound γ, thatis, the difference in the sensitivity, and thus converted to a weightratio or a molar ratio, whereby the abundance ratio can be determined.

The compound β has one or more hydroxyl groups obtained by ring openingresulting from addition of one or more epoxy groups to a carboxylicacid. The hydroxyl group contained in an epoxy compound is known tocontribute to adhesiveness of an epoxy resin. In an epoxy compoundproduced by an epichlorohydrin method, a hydroxyl group is contained ina ratio of around 10% and is known to contribute to the adhesiveness.The conventional epoxidation reaction using an onium salt cannot producea compound corresponding to the compound β and therefore, the content ofa hydroxyl group-containing component in the obtained epoxy compositionis very small, leaving the fear of insufficient adhesiveness. The epoxycomposition obtained by the production method of the present inventioncontains a given amount of the compound β and therefore, is excellent interms of lack of the fear above.

<Production Method of Epoxy Resin>

An epoxy resin can be produced by polymerizing the epoxy compoundobtained by the production method of the present invention or the epoxycomposition of the present invention. The polymerization reaction may beperformed by applying a known method and specifically, can be performed,for example, by the method described in JP-A-2007-246819.

<Epoxy Resin>

The high-purity epoxy resin obtained by the method of the presentinvention can be used in the fields of electronic material, opticalmaterial, adhesive, building, etc. Use of the resin makes it possible toavoid corrosion or short circuit occurring due to impurities when usedas an electronic component material such as semiconductor sealingmaterial, printed wiring board, build-up wiring board and solder resist,or reduce or avoid the deterioration of coloration when used as anoptical material such as sealant of a lighting unit.

Incidentally, the catalyst composition for an epoxidation reaction ofthe present invention can be utilized also as an oxidant for anoxidation reaction other than an epoxidation reaction, preferably at thetime of oxidation of an olefin.

EXAMPLES

The present invention is described in greater detail below by referringto Examples, but the present invention should not be construed as beinglimited to these Examples.

<¹H-NMR Analysis Conditions>

Apparatus: AVANCE400, manufactured by BRUKER, 400 MHz

Solvent: deuterium chloroform containing 0.03 vol % tetramethylsilane

Cumulated number: 128 times

The date in Examples show the 8 value in ¹H-NMR (400 MHz, CDCl₃).

Also, the underline in the NMR date described in Examples indicates theproton position identified.

<LC Analysis Conditions>

LC Apparatus: SPD-10Avp, manufactured by Shimadzu Corporation

Temperature: 35° C.

Column: Mightysil RP-18GP aqua 150-4.6 (5 μm) (produced by KantoChemical Co., Inc.)

(The following conditions are designated as Analysis Condition 1 andunless otherwise indicated, LC analysis was performed under thiscondition.)

Detector: UV 280 nm

Eluent: acetonitrile/aqueous 0.1% trifluoroacetic acid solution=90/10(vol %)

Flow rate: 0.5 ml/min

(The following conditions are designated as Analysis Condition 2.)

Detector: UV 254 nm

Eluent: acetonitrile/aqueous 0.1% trifluoroacetic acid solution60/40→100/0 (vol %), 20 minutes, and thereafter, kept at 100/0 (vol %)for 10 minutes

Flow rate: 0.5 ml/min

<LC-Mass Analysis Conditions>

LC Apparatus: Waters Acquity

Temperature: 40° C.

Column: UPLC BEH C₁₈ 2.1×100 mm (1.7 μm)

Eluent: acetonitrile/aqueous 20 mM ammonium acetate solution=50/50

(vol %)→100/0 in 10 min, kept at 100/0 for 10 min

Flow rate: 0.25 m1/min

MS Apparatus: Waters LCT Premier XE

Ionization method: ESI(+) method

<GC Analysis Conditions>

Apparatus: GC-1700, manufactured by Shimadzu Corporation

Column: ZB-5 (30 m×0.25 mmφ, 0.25 μm), manufactured by phenomenex

Detector: hydrogen flame ion detector (FID)

Carrier gas (nitrogen flow rate): 28 ml/min

Column temperature: raised from 100° C. to 300° C. at 10° C./min

INJ Temperature: 250° C.

DET Temperature: 300° C.

<GC/Mass Analysis Conditions>

GC Apparatus: GC-2010, manufactured by Shimadzu Corporation

MS Apparatus: GCMS-QP2010Plus, manufactured by Shimadzu Corporation

Column: DB-5 25 M×0.25 (0.25μ)

Ionization method: EI method and CI method

<RI Analysis Conditions>

RI Apparatus: JASCO RI-930, manufactured by JASCO Corporation

Temperature: 35° C.

Column: ODS-3 150-4.6 (5 μm) (manufactured by GL Sciences Inc.

Eluent: acetonitrile

Flow rat: 0.5 ml/min

As for the chlorine content (ppm by weight), the combined total chlorineamount of inorganic and organic components was measured by the followingmethod. The sample was burned, absorbed by an absorbing liquid and thenmeasured by ion chromatography. The burning apparatus used was AQF-100manufactured by Mitsubishi Chemical Corporation, and the ionchromatograph used was DX-500 manufactured by DIONEX. In the ionchromatograph, Ion Pac AS12A manufactured by DIONEX was used for thecolumn, and the detection was performed by measuring the electricalconductivity.

The tungsten content (ppm by weight) was measured by the followingmethod. From 0.1 to 0.5 g of the sample was weighted, 2 ml of sulfuricacid was added, and after heating and carbonization, nitric acid andhydrogen peroxide were further added, followed by heating to effect wetdigestion. Thereto, 2 ml of aqueous hydrogen peroxide was added andafter heating, the mixture was diluted to about 40 ml total with purewater. Furthermore, 2 ml of aqueous hydrogen peroxide was added, and themixture was diluted to 50 ml with pure water. The resulting solution wasanalyzed by ICP-AES (ULTIMA 2C, manufactured by HORIBA Jobin Yvon).

The nitrogen content (ppm by weight) was measured by the followingmethod. 8 mg of the sample was burned in an oxygen and argon atmosphere,and the decomposition gas generated was measured by a trace nitrogenanalyzer (Model TN-10, manufactured by Mitsubishi Chemical AnalytechCo., Ltd.) using a combustion and reduced pressure chemiluminescencemethod. Also, as the standard sample, aniline dissolved in toluene wasused.

The pH of the aqueous phase was measured using pH test papers,Comparator (produced by Johnson Test Papers), for the pH of 1.0 to 3.5and the pH of 3.6 to 5.1.

(Epoxidation Reaction Raw Material)

As 3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl(another name: 3,3′,5,5′-tetramethylbiphenyl-4,4′-diallyl ether), acompound synthesized by a method in conformity with Example 2 ofJP-A-2011-213716 was used. The compound contained 23 ppm of chlorine,and the purity was 99.9% (LC area %, Analysis Condition 1).

As 1,5-cyclooctadiene, a reagent produced by Tokyo Chemical IndustryCo., Ltd. was used.

As for the diol compound γ (Compound 23) contained in the epoxy compound(Compound 21), a specimen was synthesized by the method described inReference Example 1 and using this specimen, the assignment of NMR peaksand the retention time and UV absorption intensity by LC analysis wereconfirmed and used for the determination of the content of Compound 23in Compound 21.

As for the ester compound β (Compound 22) in Examples 12, 14, 16, 18,20, 22, 25 and 26, a specimen was synthesized according to the methoddescribed in Reference Example 2, and the NMR analysis of this specimenwas performed to confirm the assignment of each peak of NMR. The NMRanalysis of Compound 21 was performed based thereon, and the resultswere used for the determination of the content of Compound 22 inCompound 21. In other Examples, the content of Compound 22 in Compound21 was determined by analogy with NMR of the compound obtained inReference Example 2.

Incidentally, the molecular weight of the ester compound β (Compound 22)in Examples 2, 8 and 9 was confirmed by LC-Mass. m/z: 470.3.

For determining the abundance ratio of the compound β or the compound γto the compound α, the composition obtained by the epoxidation reactionwas subjected to LC analysis (in Example 28, GC analysis) to measure theLC area % of each component.

As for the abundance ratio of the compound γ to the compound α, the peakarea ratio of the compound γ to the compound α determined by LC analysis(in Example 28, GC analysis) was corrected for the detection sensitivityof each compound and converted to a molar ratio. The detectionsensitivity of each compound was determined by previously preparing aspecimen of each compound with a purity of 95% or more and calculatingthe sensitivity from the approximation (purity/100 estimated by molarnumber×LC area %) of the net molar number of the compound and the LCpeak area thereof.

Subsequently, the composition obtained by the epoxidation reaction wassubjected to NMR analysis. The abundance ratio of the compound β wasdetermined by comparing the integrated value of proton peaks of theterminal methyl group of a hexanoic acid ester, the tert-butyl group ofa tert-butylbenzoic acid ester, etc., which are easy to specify andintegrate, with the integrated value of peaks of the epoxy compound α.

The contents of the compounds β and γ are expressed by the abundanceratio to the epoxy compound α, that is, the molar ratio (mol %) based onthe epoxy compound α that is taken as 100.

In Examples, in the process of synthesizing (21) by an epoxidationreaction, a slight amount of a compound (a compound of m/z 370.2 inLC-Mass) considered to result from aldehyde isomerization and subsequentoxidation of an epoxy ring by heat or an acid during the reaction isproduced in addition to the compounds β and γ. Both of the compoundabove and the compound γ have higher polarity than the epoxy compound α(21) and give a faster retention time than the compound α (21) in LCanalysis. In Examples, these compounds giving a faster retention timethan the epoxy compound α (21) are sometimes collectively referred to as“polar compound”.

Example 1 Synthesis of Onium Salt [1]

To a mixed solution containing 5.0 g (27 mmol) of triethanolaminehydrochloride, 200 ml of toluene and 10.9 g (4 times mol/substrate) oftriethylamine, 10.8 g (3.0 times mol/substrate) of hexanoic acidchloride was added dropwise under ice-water cooling. After the reactionwith stirring at room temperature for 1 day, the reaction solution waswashed twice with water, i.e., with 150 ml and then with 100 ml, andthen concentrated to obtain 9.8 g of crude triethanolamine trihexanoate.

A 7.8 g portion of the crude triethanolamine trihexanoate obtained bythe method above was subjected to column purification (200 g of silicagel 60N, developing system: hexane/ethyl acetate=4/1) to obtain 1.63 gof triethanolamine trihexanoat with a purity of 91.2% (GC area %). M+H⁺:444.3 (GC-Mass).

The NMR data of the triethanolamine trihexanoate were as follows.

0.90 (9H, t, —CH3), 1.30 (12H, m, CH3-CH2-CH2—), 1.61 (6H,m,—CH2—CH2-CO), 2.30 (6H, t, J=7.56,—CH2—CH2-CO), 2.83 (6H, t, J=6.08,N—CH2-), 4.12 (6H, t, J=6.08, —CH2-O—CO—).

4 ml of toluene, 0.46 g (1.0 times mol/substrate) of dimethyl sulfateand 0.51 g (1.0 times mol/substrate) of potassium carbonate were addedto 1.63 g of triethanolamine trihexanoate above and reacted at 80° C.for 5.5 hours. After confirming the conversion of the raw material bythe disappearance of the peak attributable to the ethylene moiety of thetriethanolamine trihexanoate in NMR analysis, the reaction solution waswashed with 5 ml of water, washed three times with 5 ml of 20% sulfuricacid solution, further washed with 5 ml of water and then concentratedto obtain 2.1 g of crudeN-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium hydrogen sulfate.m/z: 458.3 (LC-Mass) and purity: 75% (RI). This product was used withoutpurification in the epoxidation reaction.

Incidentally, in the following,“N-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium hydrogensulfate” is sometimes referred to as “Onium Salt [1]”.

The NMR measurement data of Onium Salt [1] are as follows.

N-Methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium hydrogen sulfate

0.90 (9H, t, —CH3), 1.31 (12H, m, CH3-CH2-CH2—), 1.61 (6H,m-CH2-CH2-CO), 2.33 (6H, t, —CH2-CO), 3.38 (3H, s, N—CH3), 3.92 (6H, br,N—CH2-), 4.60 (6H, br, —CH2-O—CO—), 5, 78 (1H, br, HO—SO2).

Example 2 Epoxidation Reaction Using Onium Salt [1]

A mixed solution containing 5.0 g (15.5 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl, 512 mg(10% mol/substrate) of sodium tungstate dihydrate, 1.97 ml (11%mol/substrate) of an aqueous 8.5% (weight/volume) phosphoric acidsolution, 432 mg (5% mol/substrate) of crudeN-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium hydrogen sulfate,and 3 ml of toluene was heated at 65° C. Under a nitrogen stream, thesolution above was added with 0.5 ml (0.5 times mol/substrate) of 45%hydrogen peroxide 6 times every hour and further held at 65 to 68° C.for 7 hours, thereby performing the reaction for a total of 12 hours. Itwas confirmed by the LC analysis above that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 81% (LC area %).

In addition, 7.0% of 3,3′,5,5′-tetramethylbiphenyl-4,4′-monoallyl ethermonoglycidyl ether (hereinafter, this compound is sometimes referred toas a monoepoxy compound) as a reaction intermediate, and 9.5% of a polarcompound containing the above-described diol compound γ (both are LCarea %) were produced.

Here, the “LC area” indicates the peak area of the target compound ofanalysis, which is obtained by liquid chromatograph (LC) analysis, and“LC area %” indicates the ratio of the peak area of the target compoundto the peak area of the total amount of the composition.

After the completion of reaction, 7.5 ml of toluene was additionallyadded and then, the aqueous phase was separated, washed twice with 5 mlof water and washed in sequence with 5 ml of an aqueous 5% sodiumthiosulfate solution and with 5 ml of water. Furthermore, 10 ml of anaqueous 1N sodium hydroxide solution was added and after stirring for 1hour, the aqueous phase was discharged. The toluene phase was analyzedby NMR, and it was confirmed by the disappearance of the peakattributable to the ethylene moiety ofN-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium hydrogen sulfatethat Onium Salt [1] was hydrolyzed. Washing with the same aqueous sodiumhydroxide solution and NMR analysis were repeated three times, and theresulting solution was washed with 10 ml of water. The obtained toluenephase was concentrated to obtain 3.8 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) as acrude crystal. The purity was 86.4%, and the yield was 60%. This crudcrystal contained 2.7 mol % of the ester compound β (Compound 22) and5.2 mol % of the diol compound γ (Compound 23).

The NMR data of the compound before and after the reaction were asfollows.

3,3′,5,5-Tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl

2.32 (12H, s, —CH3), 4.34 (4H, dt, O—CH2-), 5.27 (2H, ddd, —CH═CH2),5.44 (2H, ddd, —CH═CH2), 6.13 (2H, m,—CH═CH2), 7.18 (4H, s, —C6H2(Me)2-).

3,3′,5,5′-Tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21)

2.34 (12H, s, —CH3), 2.75 (2H, dd, —CH2-), 2.90 (2H, dd, —CH2-), 3.38(2H, m, —CH—), 3.73 (2H, dd, —CH2-), 4.07 (2H, dd, —CH2-), 7.18 (4H, s,—C6H2 (Me)2-).

The contents of chlorine, tungsten and nitrogen in the compound wereanalyzed by the methods described above. The results are shown in Table1.

Example 3 Synthesis of Onium Salt [2]

A mixed solution containing 0.92 g (4.1 mmol) of ethyl bromohexanoate,1.0 g (1 times mol/substrate) of dioctylamine, 5 ml of ethanol and 0.57g (1 times mol/substrate) of potassium carbonate was relaxed for 10hours. After additionally adding 0.46 g of ethyl bromohexanoate and 0.29g of potassium carbonate and relaxing the mixed solution for another 5hours, 0.25 g of dioctylamine was additionally added, and the mixedsolution was relaxed for 12 hours. Disappearance of ethyl bromohexanoateand dioctylamine was confirmed by NMR analysis and thereafter, 0.52 g (1times mol/substrate) of dimethyl sulfate and 0.57 g (1 timesmol/substrate) of potassium carbonate were added and reacted at 60° C.for 2 hours. Subsequently, 0.52 g of dimethyl sulfate and 0.57 g ofpotassium carbonate were additionally added and reacted at 60° C. foranother 2 hours, and furthermore, 0.18 g of dimethyl sulfate and 0.15 gof potassium carbonate were additionally added and reacted at 60° C. for2 hours. Disappearance of N-(6-ethoxy-6-oxohexyl)-N,N-dioctylamine as areaction intermediate was confirmed by NMR analysis and thereafter, theinsoluble matter was separated by filtration and concentrated to obtain2.39 g of N-(6-ethoxy-6-oxohexyl)-N-methyl-N,N-dioctylammoniummonomethyl sulfate. Yield: 91%.

1.0 g of N-(6-ethoxy-6-oxohexyl)-N-methyl-N,N-dioctylammonium monomethylsulfate obtained by the method above was dissolved in 2 ml of toluene,and 1 ml of 20% sulfuric acid solution was added, followed by stirringat room temperature for 20 minutes. After discharging the aqueous phase,1 ml of 20% sulfuric acid solution was again added, followed by stirringat room temperature for 20 minutes. After discharging the aqueous phase,1 ml of water was added, followed by stirring at room temperature for 20minutes, and the aqueous phase was discharged. The residue wasconcentrated to obtain 1.0 g ofN-(6-ethoxy-6-oxohexyl)-N-methyl-N,N-dioctylammonium hydrogen sulfate(hereinafter, Onium Salt [2]). This product was used withoutpurification in the epoxidation reaction.

The NMR data of Onium Salt [2] obtained are as follows.

N-(6-Ethoxy-6-oxohexyl)-N-methyl-N,N-dioctylammonium hydrogen sulfate

0.90 (6H, m, —CH3), 1.15-1.5 (25H, m, —CH2-+—CH3), 1.5-1.8 (8H, m,—CH2-), 2.3-2.4 (2H, m, —CH2-CO—), 3.23 (3H, s, N—CH3), 3.2-3.4 (6H, m,N—CH2-), 4.12 (2H, dd, —CH2-O—CO—), 5.66 (1H, br, HO—SO2).

Example 4 Epoxidation Reaction Using Onium Salt [2]

The reaction was performed in the same manner by the same method as inExample 2 by using, as the ammonium salt,N-(6-ethoxy-6-oxohexyl)-N-methyl-N,N-dioctylammonium hydrogen sulfate(5% mol/substrate) in place ofN-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium hydrogen sulfate.The reaction yield: 80% (LC area %). The obtained crude crystal ofCompound 21 contained 1.1 mol % of the ester compound β (Compound 22).The content of tungsten in the compound was measured by the methoddescribed above. The measurement results are shown in Table 1.

Example 5 Synthesis of Onium Salt [3]

A mixed solution containing 5.0 g (14.1 mol) of trioctylamine, 25 ml oftoluene and 1.92 g (1.0 times mol/substrate) of methyl bromoacetate washeated at 40° C. for 4 hours. After confirming disappearance of methylbromoacetate by NMR analysis, the reaction solution was washed twicewith 25 ml of an aqueous 8.5% phosphoric acid solution to obtain atoluene solution of 0.57 mol/LN,N,N-trioctyl-N-(2-methoxy-2-oxoethyl)ammonium phosphate (hereinafter,Onium Salt [3]). This product was used without purification in theepoxidation reaction.

The NMR data of Onium Salt [3] obtained are as follows.

N,N,N-Trioctyl-N-(2-methoxy-2-oxoethyl)ammonium phosphate

0.88 (9H, t, —CH3), 1.20-1.40 (30H, m, —CH2-), 1.76 (6H, m, —CH2-),3.60-3.67 (6H, m, —CH2-), 3.81 (3H, s, —CH3), 4.85 (2H, s-N—CH2-).

Example 6 Epoxidation Reaction Using Onium Salt [3]

The reaction was performed in the same manner by the same method as inExample 2 by using, as the ammonium salt,N,N,N-trioctyl-N-(2-methoxy-2-oxoethypammonium phosphate (5%mol/substrate). The reaction stopped proceeding 4 hours after theinitiation of the reaction, and the reaction yield was 23% (LC area %).The NMR analysis of the reaction mixture was performed by the samemethod as in Example 2, as a result, disappearance of the2-methoxy-2-oxoethyl moiety of theN,N,N-trioctyl-N-(2-methoxy-2-oxoethyl)ammonium salt was confirmed,suggesting that decomposition of Onium Salt [3] occurred.

Comparative Example 1 Epoxidation Reaction Using MethyltrioctylammoniumHydrogen sulfate

150.0 g (0.47 mol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl wasreacted by the same method as in Example 2 by usingmethyltrioctylammonium hydrogen sulfate (5% mol/substrate) as theammonium salt. The reaction yield of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was 84% (LC area %).After the completion of reaction, the reaction solution was treated bythe same method to obtain 147 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether as a crude crystal.Yield: 76% and purity: 91.2% (LC area %, LC Analysis Condition 2). Thiscrude crystal contained methyltrioctylammonium salt, and the contentthereof was estimated by NMR analysis to be 6 mol % (expressed by theratio based on 3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether thatis taken as 100). The residual amount of each of nitrogen and tungstenwas measured by inorganic analysis. The analysis results are shown inTable 1.

Comparative Example 2

After adding 10.5 ml of methanol to 1.5 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether obtained by themethod of Comparative Example 1, the mixture was stirred and crystalizedat 50° C. for 2 hours and cooled to 6° C., and 0.89 g of a crystal wascollected by filtration. Yield: 62%. Purity: 95.2% (LC area %, LCAnalysis Condition 2). This crystal contained methyltrioctylammoniumsalt, and the content thereof was 1.75 mol % (the same NMR analysis asabove; corresponding to a residual nitrogen amount of 690 ppm).

Example 7 Synthesis Method of Onium Salt [1′] (with the Counter Cationbeing Monomethylsulfuric Acid)

A mixed solution containing 20.0 g (207 mmol) of triethanolaminehydrochloride, 60 ml of octane, 43.3 g (3.0 times mol/substrate) ofhexanoic acid and 5.28 g of sulfuric acid was heated in an oil bath at135° C. and reacted for 61 hours while distilling off the occurringwater. After allowing the reaction system to cool, 200 ml of ethylacetate and 400 ml of a saturated sodium bicarbonate solution wereadded, and the mixture was stirred. Thereafter, the aqueous phase wasdischarged, and the organic phase was washed with 100 ml of water. Theobtained compound was a mixture of hexanoic acid monoester, diester andtriester, and the esterification ratio (the proportion of the esterifiedhydroxyl group determined from the H integration ratio in NMR analysis)was 79%.

The crude triethanolamine trihexanoate obtained by the method above wassubjected to column purification (silica gel 60N, 300 g, developingsystem: hexane/ethyl acetate=10/1→>5/1) to obtain 15.6 g oftriethanolamine trihexanoate with a purity of 98.3% (GC). The yield was33%.

To 0.34 g (0.78 mmol) of triethanolamine trihexanoate obtained above,1.1 ml of toluene and 0.12 g (1.2 times mol/triethanolaminetrihexanoate) of dimethyl sulfate were added and reacted at 90° C. for 2hours. As a result,N-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammonium monomethylsulfate (hereinafter, referred to as Onium Salt [1′]) in an yield of 84%(molar ratio determined from the H integration degree of ethylene chainin NMR analysis). This reaction solution was used directly withoutpurification in the epoxidation reaction.

Example 8 Epoxidation Reaction Using Onium Salt [1′]

A solution prepared by dissolving 5.0 g (15.5 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl in 6.3 mlof toluene was washed with 15 ml of an aqueous solution containing 1 wt% of anhydrous sodium sulfate and 1 vol % of acetic acid, then washedwith a mixed solution containing 0.23 ml of an aqueous 3 wt % sodiumpyrophosphate solution, 0.06 ml of a 10 wt % ethylenediaminetetraaceticacid solution and 15 ml of water, and further washed with 10 ml ofwater, and to the obtained toluene layer, 511 mg (10% mol/substrate) ofsodium tungstate dihydrate, 0.9 ml (5% mol/substrate) of an aqueous 8.5%(weight/volume) phosphoric acid solution, 2 ml of water and a toluenesolution of N-methyl-N,N,N-tri[2-(pentylcarbonyloxy)ethyl]ammoniummonomethyl sulfate obtained above were added, followed by stirring.Furthermore, an aqueous phosphoric acid solution was added to theresulting mixed solution, whereby the pH of the aqueous phase of themixed solution was adjusted to 4.8. The amount of the aqueous phosphoricacid solution added here was 0.5 ml (3% mol/substrate). The mixedsolution was heated at 65° C. and thereafter, under a nitrogen stream,added with 0.5 ml (0.5 times mol/substrate) of 45% hydrogen peroxide atotal of 5 times, that is, at the initiation of reaction and after 1hour, 2 hours, 3 hours and 6 hours therefrom, at an inner temperature of65 to 68° C. When the reaction was started, an aqueous 1N sodiumhydroxide solution was added in an amount of 0.4 ml after 1.5 hours, 0.1ml after 4.5 hours, and 0.1 ml after 6.5 hours, to adjust the pH of theaqueous solution to a range of 3.0 to 3.5. The reaction was performedfor a total of 8 hours at an inner temperature of 65 to 68° C., and itwas confirmed by the LC analysis above that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 82% (LC area %). In addition, production of 11% (LCarea %) of a monoepoxy compound as a reaction intermediate and 6% (LCarea %) of a polar compound was confirmed.

After the completion of reaction, 7.5 ml of toluene was additionallyadded and then, the aqueous phase was separated, washed three times with5 ml of water. Furthermore, 10 ml of an aqueous 1N sodium hydroxidesolution was added and after stirring for 1 hour, the aqueous phase wasdischarged. Washing with the same aqueous sodium hydroxide solution wasrepeated three times, and the resulting solution was washed with 10 mlof water. The obtained organic phase was concentrated to obtain 4.5 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) with apurity of 83% (LC area %) as a crystal. The yield was 69%. This crystalcontained 2.4 mol % of the ester compound β (Compound 22) and 3.5 mol %of the diol compound γ (Compound 23). The contents of chlorine, tungstenand nitrogen in the compound were analyzed by the methods describedabove. The measurement results are shown in Table 1.

Example 9

After adding 15 ml of methanol to 2.0 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether obtained by themethod above, the mixture was stirred and crystalized at 50° C. for 1hour to obtain 1.8 g of a crystal of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) with apurity of 91% (LC area %). Recovery percentage: 98%. This crystalcontained 0.3 mol % of the ester compound β (Compound 22).

Example 10 Synthesis of Onium Salt [4]

The reaction was performed by the same method as in Example 8 withoutperforming the addition of an aqueous sodium hydroxide solution duringthe reaction. It was confirmed that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 77% (LC area %). In addition, production of 9% (LCarea %) of a monoepoxy compound as a reaction intermediate and 12% (LCarea %) of the compound γ resulting from ring opening of an epoxy ringdue to an acid was confirmed.

Example 11

(In the structural formula above, R²⁵ represents a C8-C18 alkyl group.)

While heating a mixed solution containing 12.0 g of Ethoquad C/12produced by Lion Akzo Corporation(N-alkyl(C8-C-18)-N,N-bis(2-hydroxyethyl)-N-methylammonium chloride;containing about 20% of isopropanol) and 200 ml of toluene, 50 ml of amixed solution of toluene and isopropanol was distilled off. Thereafter,5.0 g of triethylamine was added and after adding 6.7 g of benzoylchloride at an inner temperature of 60 to 80° C., the reaction wasperformed at an inner temperature of 65° C. for 30 minutes and at 80° C.for 2 hours. As for the change over time of the reaction system, about0.1 ml of the reaction mixture was dissolved in 1 ml of methanol, theunreacted benzoyl chloride was converted to benzoic acid methyl eater,and LC analysis was performed under Analysis Condition 2. Triethylamineand benzoyl chloride were gradually added at 80° C., and the point whereconsumption of benzoyl chloride was stopped was designated as the endpoint. The amounts of the additionally added triethylamine and benzoylchloride were 4.8 g and 3.6 g, respectively.

After the completion of reaction, 100 ml of toluene and 100 ml of waterwere added to the reaction system and after stirring, the aqueous phaseturned white turbid was discharged. When the aqueous phase was leftstanding still, an organic phase was liberated and therefore, thisorganic phase was combined with the separated organic phase and washedwith 100 ml of water to obtain 13 g of a benzoic acid ester form ofEthoquad C/12, which isN-alkyl-N,N-bis[2-(phenylcarbonyloxy)ethyl]-N-methylammonium chloride.The purity was 82% (LC area %, LC Analysis Condition 2), and the productcontained 11% (LC area %) of benzoic acid. The carbon number of thealkyl chain was estimated to be about 14 on average from the Hintegration value in NMR (hereinafter, referred to as Onium Salt [4]).

The NMR data of Onium Salt [4] obtained are as follows.

N-Alkyl-N,N-bis[2-(phenylcarbonyloxy)ethyl]-N-methylammonium chloride

0.88 (3H, —CH3), 1.0-1.4 (about 20H, br, —CH2-), 1.76 (2H, m, —CH2-),2.00 (2H, m, —CH2-), 3.63 (3H, s, N—CH3), 3.63 (2H, m-CH2-), 4.38 (4H,m, N—CH2-), 4.91 (4H, m, —CH2-CO), 7.42 (4H, dd, -Ph), 7.56 (2H, dd,-Ph), 8.00 (4H, d, -Ph).

Example 12 Epoxidation Reaction Using Onium Salt [4]

A solution prepared by dissolving 10.0 g (31.0 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl in 10 mlof toluene was washed with 30 ml of an aqueous solution containing 1 wt% of anhydrous sodium sulfate and 1 vol % of acetic acid, then washedwith a mixed solution containing 0.26 ml of an aqueous 3 wt % sodiumpyrophosphate solution, 0.12 ml of a 10% ethylenediaminetetraacetic acidsolution and 30 ml of water, and further washed with 30 ml of water, andto the obtained organic phase, 1.02 g (10% mol/substrate) of sodiumtungstate dihydrate, 1.79 ml (5% mol/substrate) of an aqueous 8.5%(weight/volume) phosphoric acid solution, 2 ml of water and 1.0 g of thebenzoic acid ester form of Ethoquad C/12 obtained above were added,followed by stirring. Under a nitrogen stream, 0.5 ml (0.5 timesmol/substrate) of 45% hydrogen peroxide was added at an innertemperature of 65 to 68° C., and thereafter, 1.79 ml (5% mol/substrate)of an aqueous phosphoric acid solution was further added to theresulting mixed solution, whereby the pH of the aqueous solution of themixed solution was adjusted to 3.5. While heating the mixed solution at65° C., 0.5 ml (0.5 times mol/substrate) of 45% hydrogen peroxide wasadded a total of 5 times, that is, after 1 hour, 2 hours, 3 hours and 6hours therefrom, and 0.1 g of the benzoic acid ester form of EthoquadC/12 was additionally added after 8 hours. The reaction was performedfor a total of 12 hours at an inner temperature of 65 to 68° C., and itwas confirmed by the LC analysis above that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 82% (LC area %). In addition, production of 8% (LCarea %) of a monoepoxy compound as a reaction intermediate and 5% (LCarea %) of a polar compound was confirmed.

After the completion of reaction, the aqueous phase was discharged, andthe residue was washed twice, that is, with 20 ml of water and with 2 mlof saturated brine, further washed twice with 20 ml of water, and thencooled to precipitate the reaction content as a solid. The supernatantwater and the toluene mixed solution were discharged by decantation, andthe remaining solvent was distilled off by blowing nitrogen, as aresult, a solid of the reaction content was obtained.

The obtained solid was added with 20 ml of an aqueous 1N sodiumhydroxide solution and after stirring for 1 hour, the aqueous phase wasdischarged. After repeating the same operation three times, theresulting solution was washed with 2 ml of an aqueous 5% sodiumthiosulfate solution and 20 ml of water and further washed with 20 ml ofwater, and the obtained solid was dried to obtain 8.2 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) with apurity of 94% (LC area %) as a crude crystal (yield: 70%). This crudcrystal contained 0.6 mol % of the ester compound β (Compound 22) and6.8 mol % of the diol compound γ (Compound 23).

The content of tungsten in the compound was analyzed by the methoddescribed above. The measurement results are shown in Table 1.

Example 13 Synthesis of Onium Salt [5]

A mixed solution containing 80 g (0.44 mmol) of 4-tert-butylbenzoicacid, 240 ml of toluene and 0.68 g (0.015 times mol/substrate) oftriethylamine was heated at 75° C. and thereafter, 64.1 g (1.2 timesmol/substrate) of thionyl chloride was added over 1.5 hours. Thereaction was performed at 75° C. for another 1.5 hours. After thecompletion of reaction, 100 ml of toluene was added under atmosphericpressure, 50 ml of toluene was further added under reduced-pressureconditions, and excess thionyl chloride was distilled off to obtain 90.8g of 4-tert-butylbenzoyl chloride.

To a mixed solution containing 2.0 g (10.8 mmol) of triethanolaminehydrochloride, 20 ml of toluene and 4.36 g (4 times mol/substrate) oftriethylamine, 7.0 g (3.0 times mol/substrate) of 4-tert-butylbenzoylchloride obtained by the method above was added dropwise under ice-watercooling. After the reaction with stirring at 60° C. for 5 hours, 1.42(1.3 times mol/substrate) of triethylamine and 0.4 g of triethanolaminehydrochloride were additionally added and reacted with stirring at 80°C. for 10 hours. After the completion of reaction, the reaction solutionwas washed three times with 20 ml of water and then concentrated. Theobtained crude triethanolamine trihexanoate was added with 40 ml ofhexane for crystallization, and the crystal was collected by filtrationto obtain 5.12 g of triethanolamine tri-4-tert-butylbenzoate. Purity:98.2% (LC Analysis Condition 2) and yield: 63%.

A 0.54 g (0.85 mmol) portion of the triethanolaminetri-4-tert-butylbenzoate obtained by the method above was added with 1.6ml of toluene and heated at 80° C., and the reaction was performed for3.5 hours while adding in parts 135 mg (1.2 times mol/substrate) ofdimethyl sulfate. Production ofN-methyl-N,N,N-tri[2-(4-tert-butylphenylcarbonyloxy)ethyl]ammoniummonomethyl sulfate (hereinafter, referred to as Onium Salt [5]) at aconversion ratio of 91% (LC area %, LC Analysis Condition 2) wasconfirmed. This reaction solution was used directly without purificationin the epoxidation reaction.

The NMR data of Onium Salt [5] obtained are as follows.

N-Methyl-N,N,N-tri[2-(4-tert-butylphenylcarbonyloxy)ethyl]ammoniummonomethyl sulfate

1.28 (27H, s, t-Bu), 3.58 (3H, s, —CH3), 3.67 (3H, s, CH3OSO2-), 4.26(6H, br, N—CH2-), 4.92 (6H, br, —CH2-CO), 7.38 (6H, dd, —Ar), 7.88 (6H,dd, —Ar).

Example 14 Epoxidation Reaction Using Onium Salt [5]

5.0 g (15.5 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl pretreatedby the same method as above, 3.8 ml of toluene, 512 mg (10% molsubstrate) of sodium tungstate dihydrate, 1.61 ml (9% mol/substrate) ofan aqueous 8.5% (weight/volume) phosphoric acid solution, 3.4 ml ofwater and a toluene solution ofN-methyl-N,N,N-tri[2-(4-tert-butylphenylcarbonyloxy)ethyl]ammoniummonomethyl sulfate obtained above were previously added and stirred.This mixed solution was heated at 65° C. and thereafter, under anitrogen stream, added with 0.5 ml (0.5 times mol/substrate) of 45%hydrogen peroxide a total of 5 times, that is, at the initiation ofreaction and after 1 hour, 2 hours, 3 hours and 4 hours therefrom, andthe reaction was performed for 7 hours. The pH of the aqueous layer wasadjusted to 2.5 by adding 0.5 ml of an aqueous 1N sodium hydroxidesolution halfway therethrough. It was confirmed that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 78% (LC area %, Analysis Condition 1). In addition,8.2% (LC area %) of a monoepoxy compound as a reaction intermediate and10.7% (LC area %) of a polar compound were produced.

After the completion of reaction, 25 ml of toluene was additionallyadded, the aqueous layer was discharged, and the residue was washedtwice with 10 ml of water and then washed with 12.5 ml of an aqueous 5%sodium thiosulfate solution. Furthermore, 25 ml of an aqueous 1N sodiumhydroxide solution was added and after stirring at 25° C. for 15minutes, the aqueous layer was discharged. Washing with the aqueoussodium hydroxide solution was repeated three times at an innertemperature of 35° C. for 30 minutes, and the resulting solution waswashed with 25 ml of water. It was confirmed by LC and NMR thatN-methyl-N,N,N-tri[2-(4-tert-butylphenylcarbonyloxy)ethyl]ammoniummonomethyl was hydrolyzed and disappeared. The obtained organic phasewas concentrated to obtain 4.7 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) as acrude crystal. Purity: 89.5% (LC area %, LC Analysis Condition 2) andyield: 77%. This crude crystal contained 4.6 mol % of the ester compoundβ (Compound 22) and 1.4 mol % of the diol compound γ (Compound 23).

The contents of tungsten and nitrogen in the compound were analyzed bythe methods described above. The measurement results are shown in Table1.

Example 15 Synthesis of Onium Salt [6]

To a mixed solution containing 2.40 g (13.6 mmol) of3-diethylamino-1,2-propanediol, 20 ml of toluene and 4.13 g (3 timesmol/substrate) of triethylamine, 5.8 g (2.2 times mol/substrate) of4-tert-butylbenzoyl chloride obtained by the method above was addeddropwise under ice-water cooling. The reaction was performed withstirring at 60° C. for 3 hours. The reaction yield was 98% (LC area %,LC Analysis Condition 2). After the completion of reaction, the reactionsolution was washed three times with 20 ml of water and thenconcentrated. The obtained crude3-diethylamino-1,2-propanediol-di-4-tert-butylbenzoate was purified bysilica gel column chromatography (silica gel 60N, 200 g, developingsystem; hexane/ethyl acetate=4/1→2/1) to obtain 5.5 g of3-diethylamino-1,2-propanediol-di-4-tert-butylbenzoate with a purity of98% (LC area %). Purity: 98% (LC area %, LC Analysis Condition 2) andyield: 71%.

A 0.16 g (0.30 mmol) portion of the diester obtained by the method abovewas added with 1 ml of toluene and 51 mg (1.2 times mol/substrate) ofdimethyl sulfate and reacted at 80° C. for 2 hours. Production of2,3-bis(4-tert-butyl-phenyloxy)-N,N-diethyl-N-methyl-1-propane ammoniummonomethyl sulfate (hereinafter, referred to as Onium Salt [6]) at aconversion ratio of 99% or more was confirmed by NMR analysis. Thisreaction solution was used directly without purification in theepoxidation reaction.

The NMR data of Onium Salt [6] obtained were as follows.

2,3-Bis(4-tert-butyl-phenyloxy)-N,N-diethyl-N-methyl-1-propane ammoniummonomethyl sulfate

1.37 (18H, s, t-Bu), 1.43 (6H, s, —CH3), 3.26 (3H, s, CH3-N), 3.56 (4H,m, N-CH2—CH3), 3.73 (3H, s, CH3OSO2-), 4.36 (2H, m, —CH2-O—CO), 4.58(1H, dd, —CH2-N), 4.78 (1H, dd, —CH2-N), 6.03 (1H, m, —CH—), 7.41 (2H,dd, —Ar), 7.46 (2H, dd, —Ar), 7.87 (2H, dd, —Ar), 7.96 (2H, dd, —Ar).

Example 16 Epoxidation Reaction Using Onium Salt [6]

2.0 g (6.2 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl pretreatedby the same method as above, 1.4 ml of toluene, 204 mg (10%mol/substrate) of sodium tungstate dihydrate, 0.36 ml (5% mol/substrate)of an aqueous 8.5% (weight/volume) phosphoric acid solution, 3.6 ml ofwater and a toluene solution of2,3-bis(4-tert-butyl-phenyloxy)-N,N-diethyl-N-methyl-1-propane ammoniummonomethyl sulfate obtained above were previously added and stirred.This mixed solution was heated at 65° C. and thereafter, under anitrogen stream, added with 0.1 ml (0.5 times mol/substrate) of 45%hydrogen peroxide a total of 5 times, that is, at the initiation ofreaction and after 1 hour, 2 hours, 3 hours and 6 hours therefrom, at aninner temperature of 65 to 68° C. The reaction was performed for a totalof 7 hours at an inner temperature of 65 to 68° C., and it was confirmedby the LC analysis above that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 77% (LC area %, Analysis Condition 1). In addition,11% (LC area %) of a monoepoxy compound as a reaction intermediate and8% (LC area %) of a polar compound were produced.

After the completion of reaction, 6 ml of toluene was additionallyadded, the aqueous layer was discharged, and the organic phase waswashed with 4 ml of an aqueous 5 wt % sodium thiosulfate solution.Furthermore, 4 ml of an aqueous 1N sodium hydroxide solution was addedand after stirring for 1 hour, the aqueous layer was discharged. Afterrepeating washing with the same aqueous sodium hydroxide solution fourtimes, it was confirmed by LC that2,3-bis(4-tert-butyl-phenyloxy)-N,N-diethyl-N-methyl-1-propane ammoniummonomethyl was hydrolyzed and disappeared. The obtained organic phasewas washed with 4 ml of water and then concentrated to obtain 1.9 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) with apurity of 83% (LC area %) as a crude crystal. Yield: 72%. This crudecrystal contained 5.0 mol % of the ester compound β (Compound 22) and5.1 mol % of the diol compound γ (Compound 23).

The contents of tungsten and nitrogen in the compound were analyzed bythe methods described above. The measurement results are shown in Table1.

Example 17 Synthesis of Onium Salt [7]

10.3 g (93.2 mol) of 1-chloro-2,3-propanediol and 14.1 g (1.5 timesmol/substrate) of triethylamine were heated with stirring at 80° C. for12 hours, and 10 ml of ethanol was added. After homogenizing thereaction system, hexane was added to obtain2,3-dihydroxypropyltriethylammonium chloride as a precipitate. Theremaining ethanol was azeotropically distilled off by using toluene, andthe residue was dried under reduced pressure to obtain 19.4 g of2,3-dihydroxypropyltriethylammonium chloride. Crude yield: 98%.

A mixed solution containing 3.0 g of crude2,3-dihydroxypropyltriethylammonium chloride obtained by the methodabove, 30 ml of toluene and 5.17 g (2.2 times mol/substrate) oftriethylamine was heated at 70° C., and 7.4 g (2.2 times mol/substrate)of 4-tert-butylbenzoyl chloride synthesized by the method above wasadded. The reaction was performed for 16 hours while adding 10 ml oftetrahydrofuran halfway therethrough and additionally adding 2.2 g (1.3mol/substrate) of triethylamine. After allowing to cool, theprecipitated solid in the reaction system was collected by filtration.This solid was dissolved in 50 ml of chloroform and washed twice with 10ml of water and then, the solvent was distilled off to obtain 4.8 g of2,3-bis(4-tert-butyl-phenyloxy)-N,N,N-triethyl-1-propane ammoniumchloride. Purity: 96% (LC). Yield: 92%.

A 2 g portion of the ammonium chloride obtained by the method above waspurified (developing solvent: ethanol) with 100 ml of Diaion HP120(produced by Mitsubishi Chemical Corporation) and concentrated. Theobtained residue was dissolved in 30 ml of ethyl acetate, washed twicewith 5 ml of a 10% (v/v) sulfuric acid solution and then concentrated toobtain 1.42 g of2,3-bis(4-tert-butyl-phenyloxy)-N,N,N-triethyl-1-propane ammoniumhydrogen sulfate (hereinafter, referred to as Onium Salt [7]). Purity:98% (LC area %, LC Analysis Condition 2).

The NMR data of Onium Salt [7] obtained are as follows.

2,3-Bis(4-tert-butyl-phenyloxy)-N,N,N-triethyl-1-propane ammoniumhydrogen sulfate

1.32 (18H, s, t-Bu), 1.47 (9H, s, —CH3), 3.59 (6H, m, N—CH2-CH3), 4.29(1H, m, HSO4), 4.37 (2H, m, —CH2-O—CO), 4.64 (1H, dd, —CH2-N), 4.82 (1H,dd, —CH2-N), 6.00 (1H, m, —CH—), 7.42 (4H, dd, —Ar), 7.90 (4H, dd, —Ar).

Example 18 Epoxidation Reaction Using Onium Salt [7]

5.0 g (15.5 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl pretreatedby the same method as above, 3.8 ml of toluene, 51.2 mg (10%mol/substrate) of sodium tungstate dihydrate, 1.25 ml (7% mol/substrate)of an aqueous 8.5% (weight/volume) phosphoric acid solution, 3.4 ml ofwater and 0.46 g (5% mol/substrate) of2,3-bis(4-tert-butyl-phenyloxy)-N,N,N-triethyl-1-propane ammoniumsulfate obtained above were previously added and stirred. This mixedsolution was heated at 65° C. and thereafter, under a nitrogen stream,added with 0.5 ml (0.5 times mol/substrate) of 45% hydrogen peroxide atotal of 6 times, that is, at the initiation of reaction and after 1hour, 2 hours, 3 hours, 4 hours and 6 hours therefrom. The reaction wasperformed for a total of 10 hours, that is, for 4 hours at an innertemperature of 65 to 66° C. and for 6 hours at an inner temperature of68 to 69° C., and it was confirmed by the LC analysis above that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 82% (LC area %, Analysis Condition 1). In addition,5.4% (LC area %) of a monoepoxy compound as a reaction intermediate and10.7% (LC area %) of a polar compound were produced.

After the completion of reaction, 20 ml of toluene was additionallyadded, the aqueous layer was discharged, and the residue was washedtwice with 10 ml of water and then washed with 12.5 ml of an aqueous 5%sodium thiosulfate solution. Furthermore, 25 ml of an aqueous 1N sodiumhydroxide solution was added and after stirring at 25° C. for 1 hour,the aqueous layer was discharged. Washing with the aqueous sodiumhydroxide solution was repeated three times at an inner temperature of35° C. for 30 minutes, and it was confirmed by LC and NMR that OniumSalt [7] was hydrolyzed and disappeared and tert-butylberizoic acid as ahydrolysate of Onium Salt [7] did not remain. The obtained organic phasewas washed with 25 ml of water and then concentrated to obtain 4.88 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether (Compound 21) as acrude crystal. Purity: 87.5% (LC area %, LC Analysis Condition 2).Yield: 78%. This crude crystal contained 4.5 mol % of the ester compoundβ (Compound 22) and 3.7 mol % of the diol compound γ (Compound 23).

The contents of nitrogen and tungsten in the compound were analyzed bythe methods described above. The measurement results are shown in Table1.

Example 19 Synthesis of Onium Salt [8]

A mixed solution containing 2.00 g (18.1 mmol) of3-chloro-1,2-propanediol and 4.58 g (2.5 times mol/substrate) oftriethylamine was added dropwise to 4-tert-butylbenzoyl chloridesynthesized in the same manner as above from 6.45 g (2.0 timesmol/substrate) of 4-tert-butylbenzoic acid, 4.3 g (2 timesmol/substrate) of thionyl chloride and 20 ml of toluene. The reactionwas performed at 50° C. for 7 hours. After the completion of reaction,the reaction solution was washed twice with 10 ml of water andconcentrated. The obtained crude3-chloro-1,2-propanediol-di-4-tert-butylbenzoate was crystallized byadding hexane to obtain 5.0 g of3-chloro-1,2-propanediol-di-4-tert-butylbenzoate. LC Purity: 98.5% (LCarea %, LC Analysis Condition 2) and yield: 64%.

A 1.00 g portion of the 3-chloro-1,2-propanediol-di-4-tert-butylbenzoate. obtained by the method above was added with 5.24 g (30 timesmol/substrate) of pyridine and 37 mg (0.1 times mol/substrate) ofpotassium iodide and reacted with stirring under reflux conditions for32 hours, whereby1-[2,3-bis[(4-tert-butylphenylcarbonyloxy)propyl]pyridinium chloride wasobtained at a conversion ratio of 98% with a selectivity of 62% (LC area%, LC Condition 2). After distilling off pyridine, 20 ml of hexane wasadded to the resulting residue to obtain 0.32 g of1-[2,3-bis[(4-tert-butylphenylcarbonyloxy)propyl]pyridinium chloride(hereinafter, Onium Salt [8]). Purity: 92.9% (LC area %, LC AnalysisCondition 2). Yield: 28%.

The NMR data of Onium Salt [8] obtained are as follows.

1-[2,3-Bis[(4-tert-butylphenylcarbonyloxy)propyl]pyridinium chloride

1.32 (18H, d, t-Bu), 4.91 (2H, m, —CH2-O—CO), 5.38 (2H, m, —CH2-N), 5.93(1H, m, —CH1-), 6.22 (1H, m, —CH2-N), 6.03 (111, m, —CH—), 7.42 (2H, dd,—Ar), 7.45 (2H, dd, —Ar), 7.82 (2H, dd, —Ar), 7.97 (2H, dd, —Ar), 8.40(1H, m, Py), 9.61 (2H, m, Py).

Example 20 Epoxidation Reaction Using Onium Salt [8]

An aqueous solution containing 1 wt % of anhydrous sodium sulfate and 1vol % of acetic acid, which was obtained by the same method as above,then a mixed solution of an aqueous 3 wt % sodium pyrophosphate solutionand a 10 wt % ethylenediaminetetraacetic acid solution, furthermore, 1.0g (3.1 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl washedwith water, 1.0 ml of toluene, 102 mg (10% mol/substrate) of sodiumtungstate dihydrate, 0.36 ml (5% mol/substrate) of an aqueous 8.5%(weight/volume) phosphoric acid solution, 1 ml of water and 81 mg (5%mol/substrate) of1-[2,3-bis[(4-tert-butylphenylcarbonyloxy)propyl]pyridinium chlorideobtained above were previously added and stirred. This mixed solutionwas heated at 65° C. and thereafter, under a nitrogen stream, added with0.1 ml (0.5 times mol/substrate) of 45% hydrogen peroxide a total of 5times, that is, at the initiation of reaction and after 1 hour, 2 hours,3 hours and 4 hours therefrom, at an inner temperature of 65 to 68° C.The reaction was performed for 1 hour after each addition. Thereafter,0.10 ml of an aqueous phosphoric acid solution was added to adjust thepH of the aqueous layer to 2.5, and the reaction was performed at aninner temperature of 68° C. while further adding 0.1 ml (0.5 timesmol/substrate) of 45% hydrogen peroxide twice every hour, therebyperforming the reaction for a total of 9 hours. It was confirmed that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 68%. In addition, 13.7% of a monoepoxy compound as areaction intermediate and 10.2% (LC area %) of a polar compound wereproduced.

After the completion of reaction, 10 ml of toluene was additionallyadded, the aqueous layer was discharged, and the organic phase waswashed with 5 ml of an aqueous 5% sodium thiosulfate solution.Furthermore, 5 ml of an aqueous 1N sodium hydroxide solution was addedand after stirring for 1 hour, the aqueous layer was discharged. Washingwith the same aqueous sodium hydroxide solution was repeated four times,and it was confirmed by LC and NMR that Onium Salt [8] was hydrolyzedand disappeared and tert-butylbenzoic acid as a hydrolysate did notremain. The obtained organic phase was washed with 5 ml of water andthen concentrated to obtain 0.9 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether with a purity of 68%(LC area %, LC Analysis Condition 2) as a crude crystal. Yield: 56%.This crude crystal contained 6.2 mol % of the ester compound 1 (Compound22).

The content of tungsten in the compound was analyzed by the methoddescribed above. The measurement results are shown in Table 1.

Example 21 Synthesis of Onium Salt [9]

A mixed solution containing 5 g (18.8 mmol) of 12-bromododecanoic acid,2.35 ml (1 times mol/substrate) of hexanol, 100 ml of toluene and 0.2 mlof sulfuric acid was reacted for 4 hours while azeotropically distillingoff the occurring water together with toluene, and after additionallyadding 0.47 ml (0.2 times mol/substrate) of hexanol, the reaction wasperformed for another 2.5 hours. The reaction solution was washed with100 ml of water, then with 50 ml of a saturated sodium bicarbonatesolution and further with 50 ml of water, and the solvent was distilledoff to obtain 6.3 g of 2-bromododecanoic acid hexyl ester with a purityof 99% or more. Yield: 92% (GC area %).

A 2.20 g (6.1 mmol) portion of the 12-bromododecanoic acid hexyl esterobtained by the method above and 0.78 g (1.0 times mol/substrate) ofdibutylamine were added, and the reaction was performed at 110° C. for19 hours while additionally adding 0.31 g (0.4 times mol/substrate) ofdibutylamine twice halfway therethrough. After the completion ofreaction, 20 ml of ethyl acetate was added, and the resulting solutionwas washed twice with 10 ml of water. The obtained organic layer wasconcentrated and then subjected to column purification (Silica 60N, 100g, developing solvent: hexane/ethyl acetate=4/1→2/1) to obtain 1.68 g of12-N,N-dibutyldodecanoic acid hexyl ester. Yield: 67%.

A 0.165 g (0.4 mmol) portion of the 12-N,N-dibutyldodecanoic acid hexylester obtained by the method above was added with 1.2 ml of toluene and57.5 mg (1.5 times mol/substrate) of dimethyl sulfate and reacted at 70°C. for 3 hours. Production of N,N-diethyl-N-methyl-1-dodecanoic acidhexyl ester ammonium methylsulfate (hereinafter, referred to as OniumSalt [9]) at a conversion ratio of 99% or more was confirmed by NMRanalysis. This reaction solution was used directly without purificationin the oxidation reaction.

The NMR data of Onium Salt [9] obtained are as follows.

N,N-diethyl-N-methyl-1-dodecanoic acid hexyl ester ammoniummethylsulfate

0.85-1.10 (9H, m, —CH3), 1.25-1.80 (34H, m, —CH2-CH2-CH2-), 2.38 (2H, m,—CO—CH2-), 3.07 (3H, s, N—CH3), 3.21 (6H, m, N—CH2-), 3.83 (3H, s,CH3SO2-), 4.12 (2H, m, —COO—CH2).

Example 22 Epoxidation Reaction Using Onium Salt [9]

2.0 g (6.2 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl pretreatedby the same method as above, 1.2 ml of toluene, 0.205 g (10%mol/substrate) of sodium tungstate dihydrate, 0.64 ml (9% mol/substrate)of an aqueous 8.5% (weight/volume) phosphoric acid solution, 1.4 ml ofwater and a toluene solution of 12-N,N-dibutyldodecanoic acid hexylester ammonium monomethyl sulfate obtained above were previously addedand stirred. This mixed solution was heated at 65° C. and thereafter,under a nitrogen stream, added with 0.1 ml (0.5 times mol/substrate) of45% hydrogen peroxide a total of 6 times, that is, at the initiation ofreaction and after 1 hour, 2 hours, 3 hours, 4 hours and 6 hourstherefrom, at an inner temperature of 65 to 68° C. The pH of the aqueousphase during reaction was 2.0. The reaction was performed at an innertemperature of 65 to 68° C. for a total of 6 hours, and it was confirmedby the LC analysis above that3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether was produced in areaction yield of 81.3% (LC area %). In addition, 10.7% of a monoepoxycompound and 7.4% (LC area %) of a polar compound were produced.

After the completion of reaction, 20 ml of toluene was additionallyadded, the aqueous layer was discharged, and the organic phase waswashed with 10 ml of an aqueous 5% sodium thiosulfate solution.Furthermore, 10 ml of an aqueous 1N sodium hydroxide solution was addedand after stirring for 1 hour, the aqueous layer was discharged. Washingwith the same aqueous sodium hydroxide solution was repeated threetimes, and the resulting solution was washed with 8 ml of water. Theobtained organic phase was concentrated to obtain 2.08 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether as a crude crystal.Purity: 86.4% (LC area %, LC Analysis Condition 2) and yield: 82%.

A 1 g (2.4 mmol) portion of the crude crystal obtained above was addedwith 3 ml of toluene and dissolved by heating at 50° C., and 7 ml ofmethanol was added thereto. The resulting solution was cooled to 6° C.,and the precipitated crystal was collected by filtration to obtain 0.52g of a crystal of 3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether.It was confirmed by NMR that the crystal was free from Onium Salt (10)and a decomposition product of the onium salt. Purity: 95.6% (LC area %,LC Analysis Condition 2). Recovery percentage: 58%. This crystalcontained 0.7 mol % of the ester compound β (Compound 22) and 6.9 mol %of the diol compound γ (Compound 23).

Example 23 Synthesis of Onium Salt [10]

2.81 g (1.0 times mol/chlorobutanol) of hexadecyl chloroformate wasadded to 1 g (9.2 mmol) of 4-chlorobutanol, 7.4 ml of pyridine and 10 mlof toluene and reacted at room temperature for 3 hours. The precipitatedpyridine hydrochloride was separated by filtration using a small amountof toluene, whereby 37 g of a mixed solution of 4-chlorobutyl hexadecylcarbonate, pyridine and toluene. A 1 g portion of the obtained solutionwas reacted for 10 hours while additionally adding 2 ml of pyridinehalfway therethrough. After confirming by NMR analysis of the reactionsolution that hexadecyl chloroformate disappeared, pyridine wasdistilled off, and hexane was added to the resulting residue to obtain acrystal. This crystal was dissolved in ethanol and after filteringinsoluble matters, the resulting solution was concentrated to obtain0.11 g of 1-[(hexadecyloxycarbonyl)oxy]butyl]pyridinium chloride(hereinafter, referred to as Onium Salt [10]). Yield: 95% or more.Purity: 90% or more (NMR).

The NMR data of Onium Salt [10] obtained are as follows.

1-[(Hexadecyloxycarbonyl)oxy]butyl]pyridinium chloride

0.88 (3H, dd, —CH3), 1.2-1.4 (26H, m, —CH2-), 1.66 (2H, m, —CH2-), 1.85(2H, m, —CH2-), 2.20 (2H, m, —CH2-), 4.11 (2H, dd, —CH2-), 4.20 (2H, dd,—CH2-), 5.20 (2H, dd, N—CH2-), 8.09 (2H, dd, Py), 8.46 (1H, dd, Py),9.53 (2H, dd, Py).

Example 24 Epoxidation Reaction Using Onium Salt [10]

1.5 g (4.7 mmol) of3,3′,5,5-tetramethyl-4,4′-bis(2-propen-1-yloxy)-1,1′-biphenyl pretreatedby the same method as above, 1 ml of toluene, 1 ml of octane, 0.154 g(10% mol/substrate) of sodium tungstate dihydrate, 0.48 ml (9%mol/substrate) of an aqueous 8.5% (weight/volume) phosphoric acidsolution, 1.0 ml of water and 0.106 g (5% mol/substrate) of1-[(hexadecyloxycarbonyl)oxy]butyl]pyridinium chloride obtained abovewere previously added and stirred. This mixed solution was heated at 65°C. and thereafter, under a nitrogen stream, added with 0.5 ml (0.5 timesmol/substrate) of 45% hydrogen peroxide a total of 6 times, that is, atthe initiation of reaction and after 1 hour, 2 hours, 3 hours, 4 hoursand 6 hours therefrom. The pH of the aqueous phase during reaction wasabout 3.0. The reaction was performed for a total of 17 hours, that is,for 7 hours at an inner temperature of 65 to 66° C. and for 10 hours atan inner temperature of 68 to 69° C., and it was confirmed by the LCanalysis above that 3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl etherwas produced in a reaction yield of 53.7% (LC area %, Analysis Condition1). In addition, 10.3% (LC area %) of a monoepoxy compound as a reactionintermediate and 22.0% (LC area %) of a polar compound were produced.

After the completion of reaction, 7.5 ml of toluene was additionallyadded, the aqueous layer was discharged, and the residue was washedtwice with 7.5 ml of water and then washed with 7.5 ml of an aqueous 5%sodium thiosulfate solution. Furthermore, 7.5 ml of an aqueous 1N sodiumhydroxide solution was added and after stirring at 25° C. for 1 hour,the aqueous layer was discharged. Washing with the aqueous sodiumhydroxide solution was repeated three times at an inner temperature of30° C. for 30 minutes, and it was confirmed by LC and NMR that OniumSalt [11] was hydrolyzed and disappeared. The obtained organic phase waswashed with 25 ml of water and then concentrated to obtain 0.94 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether as a crude crystal.Purity: 63.0% (LC area %, LC Analysis Condition 2). Yield: 36%.

Example 25

After adding 14 ml of methanol to 2.0 g of the3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether crude crystalobtained in Example 14, the mixture was stirred and crystalized at 50°C. for 3 hours and cooled to 6° C. and thereafter, the crystal wascollected by filtration to obtain 1.55 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether with a purity of90.9% (LC area %, LC Analysis Condition 2). Recovery percentage: 79%.This crystal contained 2.6 mol % of the ester compound β (Compound 22)and 0.6 mol % of the diol compound γ (Compound 23). The contents ofnitrogen and chlorine in the compound were analyzed by the methodsdescribed above. The measurement results are shown in Table 1.

Example 26

After adding 3 ml of methanol to 0.69 g of the3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether crude crystalobtained in Example 16, the mixture was stirred and crystalized at 50°C. for 1 hour and cooled to 6° C. and thereafter, the crystal wascollected by filtration to obtain 0.52 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether with a purity of90.4% (LC area %, LC Analysis Condition 2). Recovery percentage: 80%.This crystal contained 2.0 mol % of the ester compound β (Compound 22)and 1.2 mol % of the diol compound γ (Compound 23). The content ofnitrogen in the compound was analyzed by the method described above. Themeasurement results are shown in Table 1.

Example 27

After adding 3 ml of toluene to 2.0 g of the3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether crude crystalobtained in Example 18, the mixture was heated/dissolved at 50° C., thenadded with 14 ml of methanol and cooled to 6° C. and thereafter, thecrystal was collected by filtration to obtain 1.38 g of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether with a purity of96.1% (LC area %, LC Analysis Condition 2). Recovery percentage: 71%.This crystal contained 0.2 mol % of the ester compound (3 and 0.5 mol %of the diol compound γ.

The content of nitrogen in the compound was analyzed by the methoddescribed above. The measurement results are shown in Table 1.

Example 28 Epoxidation Reaction of 1,5-Cyclooctadiene Using Onium Salt[7]

3.0 g (27.7 mmol) of 1,5-cyclooctadiene (produced by Tokyo ChemicalIndustry Co., Ltd.), 9 ml of toluene, 0.183 g (2% mol/substrate) ofsodium tungstate dihydrate, 0.32 ml (1% mol/substrate) of an aqueous8.5% (weight/volume) phosphoric acid solution, 3.4 ml of water and 0.16g (1% mol/substrate) of the2,3-bis(4-tert-butyl-phenyloxy)-N,N,N-triethyl-1-propane ammoniumhydrogen sulfate (Onium Salt [7]) obtained above were added and stirred.This mixed solution was heated at 50° C. and thereafter, under anitrogen stream, added with 0.9 ml (0.5 times mol/substrate) of 45%hydrogen peroxide a total of 6 times, that is, at the initiation ofreaction and after 1 hour, 2 hours, 3 hours, 5 hours and 7 hourstherefrom. The pH of the aqueous phase 2 hours after the initiation ofreaction was 4.8. The reaction was performed for a total of 9 hours atan inner temperature of 50 to 51° C. It was confirmed by the GC analysisabove that 1,2,5,6-diepoxycyclooctane was produced in a reaction yieldof 90.2% (GC area %). In addition, 6.6% (LC area %) of a monoepoxycompound as a reaction intermediate and 3.2% (GC area %) of a compoundresulting from ring opening of epoxy were produced.

After the completion of reaction, 10 ml of toluene was additionallyadded, the aqueous layer was discharged, and the residue was washed with3 ml of water and then washed with 10 ml of an aqueous 5% sodiumthiosulfate solution. Furthermore, 10 ml of an aqueous 1N sodiumhydroxide solution was added and after stirring at 25° C. for 15minutes, the aqueous layer was discharged. Washing with the aqueoussodium hydroxide solution was repeated three times at an innertemperature of 30° C. for 30 minutes, and it was confirmed by LC and NMRthat Onium Salt [7] was hydrolyzed and disappeared and tert-butylbenzoicacid as a hydrolysate of Onium Salt [7] did not remain. The organicphase was further washed twice with 4 ml of water, and the obtainedorganic phase was concentrated to obtain 1.0 g of1,2,5,6-diepoxycyclooctane in a liquid form. Purity: 97% (GC area %) andyield: 26%. This crude crystal contained 1.8 mol % of the ester compoundβ.

The contents of tungsten and nitrogen in the compound were analyzed bythe methods described above. The measurement results are shown in Table1.

The NMR data of 1,2,5,6-diepoxycyclooctane are as follows,1,2,5,6-Diepoxycyclooctane:

1.82-2.05 (8H, m, —CH2-), 3.00 (4H, m, —CH—O—).

Reference Example 1 Synthesis of Impurity Specimen

Synthesis of3-[[3,3′,5,5′-tetramethyl-4′-(2-oxylanylmethoxy)[1,1′-biphenyl]-4-yl]oxy]-1,2-propanediol(compound γ):

50 ml of acetic acid was added to 10 g (0.028 mol) of3,3′,5,5′-tetramethylbiphenyl-4,4′-diglycidyl ether, and the mixture wasreacted at an inner temperature of about 85° C. for 9 hours. The aceticacid was distilled off under reduced pressure azeotropically togetherwith toluene to obtain 16.1 g of a residue. This was added with 60 ml ofan aqueous 1N sodium hydroxide solution and reacted at room temperaturefor 2 hours. The precipitated solid containing, as the main component,[[3,3′,5,5′-tetramethyl-[1,1′-biphenyl]-4,4′-yl]oxy]bis-(1,2-propanediol)was separated by filtration, and the filter product was washed with 100ml of ethyl acetate. The ethyl acetate of the wash liquid was combinedwith the aqueous phase and separated, and the obtained organic phase wasconcentrated. The residue obtained was purified by column chromatography(Silica 60N, 300 g, developing solvent: hexane/ethyl acetate=from 1/1 to1/2) to obtain 3.8 g of3-[[3,3′,5,5′-tetramethyl-4′-(2-oxylanylmethoxy)[1,1′-biphenyl]-4-yl]oxy]-1,2-propanediolas a crystal. Yield: 36%. Purity: 95.5% (LC area %, LC AnalysisCondition 2).

The NMR data of the diol compound γ obtained are as follows.

3-[[3,3′,5,5′-Tetramethyl-4′-(2-oxylanylmethoxy)[1,1′-biphenyl]-4-yl]oxy]-1,2-propanediol

2.34 (12H, s, —CH3), 2.72 (1H, dd, —CH2-), 2.91 (1H, dd, —CH2-), 3.44(1H, m, —CH—), 3.76 (1H, dd, —CH2-), 3.79 (2H, m, —CH2-OH), 3.90 (2H, d,O-CH2-CH(OH)), 4.08 (1H, dd, —CH2-), 4.09 (1H, m, CH—OH), 7.18 (4H, s,—C6H2 (Me)2-).

Reference Example 2 Synthesis of 4-tert-butylbenzoicacid-2-hydroxy-3-[[3,3′,5,5′-tetramethyl-4′-(2-oxylanylmethoxy)[1,1′-biphenyl]-4-yl]oxy]propylester (compound β)

0.08 g (1.5 times mol/substrate) of tert-butylbenzoyl chloride obtainedby the method above was added to a mixed solution containing 0.1 g (0.3mmol) of the diol compound obtained by the method above, 2 ml of tolueneand 0.11 ml (3 times mol/substrate) of triethylamine, and the mixturewas reacted at room temperature for 5 hours. After the reaction, 6 ml ofethyl acetate and 2 ml of water were added, followed by stirring, andthe obtained organic phase was purified by column chromatography (silica60N, 30 g, developing solvent: hexane/ethyl acetate=4/1) to obtain about50 mg of 4-tert-butylbenzoicacid-2-hydroxy-3-[[3,3′,5,5′-tetramethyl-4′-(2-oxylanylmethoxy)[1,1′-biphenyl]-4-yl]oxy]propylester (compound 13) in about 50 mg. Purity: 96.3% (LC area %, LCAnalysis Condition 2).

The NMR data of the compound β obtained are as follows.

4-Tert-butylbenzoicacid-2-hydroxy-3-[[3,3′,5,5′-tetramethyl-4′-(2-oxylanylmethoxy)[1,1′-biphenyl]-4-yl]oxy]propyl ester

1.32 (9H, s, t-Bu), 2.34 (12H, s, —CH3), 2.73 (1H, dd, —CH2-), 2.90 (1H,dd, —CH2-), 3.40 (1H, m, —CH—), 3.78 (1H, dd, —CH2-), 3.95 (2H, m,O-CH2-CH(OH)), 4.10 (1H, m, —CH2-), 4.39 (1H, m, CH—OH), 4.60 (2H, m,—CH2-OCO—), 7.18 (4H, s, —C6H2 (Me)2-), 7.49 (2H, d, t-Bu-C6H4-), 7.99(2H, d, t-Bu-C6H4-).

TABLE 1 Tungsten Nitrogen Chlorine Compound β/ (ppm by (ppm by (ppm byCompound α weight) weight) weight) (mol %) Example 2 0.06 100 31 2.7Example 4 38 — — 1.1 Example 8 0.07 84 <10 2.4 Example 9 — 10 <10 0.3Example 12 3.46 — — 0.6 Example 14 0.58 20 — 4.6 Example 16 0.45 56 —5.0 Example 18 5.2 7 — 4.5 Example 20 1.82 — — 6.2 Example 22 1.6 — —0.7 Example 25 — 7 <10 2.6 Example 26 — 15 — 2.0 Example 27 — 2 — 0.2Example 28 0.04 7 — 1.8 Comparative 142 1600 30 — Example 1

While the invention has been described in detail and with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope of the invention. This applicationis based on Japanese Patent Application (Patent Application No.2012-082319) filed on Mar. 30, 2012, Japanese Patent Application (PatentApplication No. 2012-226995) filed on Oct. 12, 2012, and Japanese PatentApplication (Patent Application No. 2013-012207) filed on Jan. 25, 2013,the contents of which are incorporated herein by way of reference.

1. A method for producing an epoxy compound, comprising reactinghydrogen peroxide with a compound having a carbon-carbon double bond inthe presence of at least one of a tungsten compound and a molybdenumcompound; and an onium salt having 20 or more carbon atoms andcontaining one or more substituents convertible to an activehydrogen-containing functional group or a salt thereof.
 2. The methodfor producing an epoxy compound as claimed in claim 1, wherein saidactive hydrogen-containing functional group is a hydroxyl group, acarboxyl group, an amino group, a mercapto group, a sulfonic acid groupor a phosphoric acid group.
 3. The method for producing an epoxycompound as claimed in claim 1, wherein at least one of phosphoric acidsand phosphonic acids (excluding an onium salt) is further allowed tocoexist in said reaction.
 4. The method for producing an epoxy compoundas claimed in claim 1, wherein said reaction is a two-phase reaction ofan aqueous phase and an organic phase and the pH of said aqueous phaseis from 2 to
 6. 5. The method for producing an epoxy compound as claimedin claim 1, wherein said onium salt is an ammonium salt, a pyridiniumsalt, an imidazolinium salt or a phosphonium salt.
 6. The method forproducing an epoxy compound as claimed in claim 1, wherein saidsubstituent convertible to an active hydrogen-containing functionalgroup or a salt thereof is an alkoxycarbonyl group or an acyloxy group.7. The method for producing an epoxy compound as claimed in claim 1,wherein said onium salt is a compound represented by any one of thefollowing formulae (1) to (3):

(in formulae (1) to (3), each of any one or more of R¹ to R⁴, any one ormore of R⁵ to R¹⁰ and any one or more of R¹¹ to R¹⁵ independentlyrepresents —Y—CO—O—Z or —Y—O—CO—Z (wherein Y represents a direct bond ora divalent aliphatic hydrocarbon group having a carbon number of 1 to25, in which a part of carbon atoms may be substituted with a heteroatomand which may have a substituent, and Z represents a monovalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, or amonovalent aromatic hydrocarbon group having a carbon number of 4 to 25,which may have a substituent), each of R¹ to R⁵, R¹¹ and R¹³, when theseare not —Y—CO—O—Z or —Y—O—CO—Z, independently represents an alkyl grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom and which may have a substituent, or abenzyl group, each of R⁶ to R¹⁰, R¹², R¹⁴ and R¹⁵, when these are not—Y—CO—O—Z or —Y—O—CO—Z, independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom and which may have a substituent, a phenylgroup, a phenoxy group, a benzyl group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group, R¹ to R¹⁵ may combine in the same compound toform a ring, provided that the total number of carbon atoms contained inR¹ to R⁴ in formula (1) is 20 or more, the total number of carbon atomscontained in R⁵ to R¹⁰ in formula (2) is 15 or more, and the totalnumber of carbon atoms contained in R¹¹ to R¹⁵ in formula (3) is 17 ormore, and X⁻ represents a monovalent anion).
 8. The method for producingan epoxy compound as claimed in claim 1, wherein in said productionmethod, after the reaction, said substituent convertible to an activehydrogen-containing functional group or a salt thereof is hydrolyzedwith a basic compound.
 9. The method for producing an epoxy compound asclaimed in claim 1, wherein said compound having a carbon-carbon doublebond is washed with an acidic aqueous solution and then subjected to thereaction.
 10. The method for producing an epoxy compound as claimed inclaim 1, wherein said compound having a carbon-carbon double bond iswashed with an aqueous chelating agent solution and then subjected tothe reaction.
 11. The method for producing an epoxy compound as claimedin claim 1, wherein in said production method, a chelating agent isallowed to coexist in the reaction.
 12. A method for producing an epoxyresin by polymerizing an epoxy compound, the production method of anepoxy resin comprising: producing an epoxy compound by the methodclaimed in claim 1; and polymerizing the epoxy compound obtained above.13. A catalyst composition for an epoxidation reaction, comprising: atleast one of a tungsten compound and a molybdenum compound, and an oniumsalt having a carbon number of 20 or more and containing one or moresubstituents convertible to an active hydrogen-containing functionalgroup or a salt thereof.
 14. The catalyst composition for an epoxidationreaction as claimed in claim 13, wherein said active hydrogen-containingfunctional group is a hydroxyl group, a carboxyl group, an amino group,a mercapto group, a sulfonic acid group or a phosphoric acid group. 15.The catalyst composition for an epoxidation reaction as claimed in claim13, which further comprises at least one of phosphoric acids andphosphonic acids (excluding an onium salt).
 16. The catalyst compositionfor an epoxidation reaction as claimed in claim 13, wherein said oniumsalt is an ammonium salt, a pyridinium salt, an imidazolinium salt or aphosphonium salt.
 17. The catalyst composition for an epoxidationreaction as claimed in claim 13, wherein said substituent convertible toan active hydrogen-containing functional group or a salt thereof is analkoxycarbonyl group or an acyloxy group.
 18. The catalyst compositionfor an epoxidation reaction as claimed in claim 13, which furthercomprises a carboxylic acid (excluding an onium salt having a carboxygroup).
 19. The catalyst composition for an epoxidation reaction asclaimed in claim 13, wherein said onium salt is a compound representedby any one of the following formulae (1) to (3):

(in formulae (1) to (3), each of any one or more of R¹ to R⁴, any one ormore of R⁵ to R¹⁰ and any one or more of R¹¹ to R¹⁵ independentlyrepresents —Y—CO—O—Z or —Y—O—CO—Z (wherein Y represents a direct bond ora divalent aliphatic hydrocarbon group having a carbon number of 1 to25, in which a part of carbon atoms may be substituted with a heteroatomand which may have a substituent, and Z represents a monovalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, or amonovalent aromatic hydrocarbon group having a carbon number of 4 to 25,which may have a substituent), each of R¹ to R⁵, R¹¹ and R¹³, when theseare not —Y—CO—O—Z or —Y—O—CO—Z, independently represents an alkyl grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom and which may have a substituent, or abenzyl group, each of R⁶ to R¹⁰, R¹², R¹⁴ and R¹⁵, when these are not—Y—CO—O—Z or —Y—O—CO—Z, independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom and which may have a substituent, a phenylgroup, a phenoxy group, a benzyl group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group, R¹ to R¹⁵ may combine in the same compound toform a ring, provided that the total number of carbon atoms contained inR¹ to R⁴ in formula (1) is 20 or more, the total number of carbon atomscontained in R⁵ to R¹⁰ in formula (2) is 15 or more, and the totalnumber of carbon atoms contained in R¹¹ to R¹⁵ in formula (3) is 17 ormore, and X⁻ represents a monovalent anion).
 20. An onium saltrepresented by the following formula (8) to (10), (12) or (31):

(in formulae (8) to (10), (12) and (31), R²⁰ represents a hydrogen atom,a halogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an alkoxycarbonyl group, an N-alkylcarbamoyl group or anN-alkylsulfamoyl group; each of R²¹ to R²³ independently represents analkyl group having a carbon number of 1 to 25, in which a part of carbonatoms may be substituted with a heteroatom, or a benzyl group; R²⁰ toR²³ may combine in the same compound to form a ring; k represents aninteger of 1 to 4; each of R³¹ and R³² independently represents adivalent aliphatic hydrocarbon group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom;R³³ represents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25, which may have a substituent; provided that aplurality of k, R²⁰ or R³¹ present in the same compound may be the sameor different and the total number of carbon atoms contained in thecation moiety in the formulae is 20 or more; and X⁻ represents amonovalent anion).
 21. A composition comprising: an epoxy compound αrepresented by the following formula (32), and a compound β having astructure where one or more glycidyl groups contained in said epoxycompound α are substituted with a 3-acyloxy-2-hydroxypropyl group(wherein said acyl group is a group represented by —CO—R³⁵ or —CO—Z):

(in formula (32), G represents a glycidyl group (2,3-epoxypropanylgroup), and said glycidyl group may be substituted with an alkyl group,a phenyl group or an alkoxycarbonyl group; A²⁰¹ represents an(m201+1)-valent aromatic or aliphatic hydrocarbon group that may have asubstituent, A²⁰² represents a divalent aromatic or aliphatichydrocarbon group that may have a substituent, and A²⁰³ represents an(m203+2)-valent aromatic or aliphatic hydrocarbon group that may have asubstituent; each of X²⁰¹ and X²⁰² independently represents a directbond or a divalent linking group that may have a substituent; p201represents 0 or 1; each of m201 and m203 independently represents aninteger of 1 or more; n201 represents an integer of 1 or more, n202represents 0 or an integer of 1 or more, and n203 represents 0 or 1;provided that in the case of n202=n203=0, when p201=0, A²⁰¹ becomesm201-valent and when p201=1, X²⁰¹ is a hydrogen atom or a monovalentgroup; and provided that a plurality of G, A²⁰¹, A²⁰², X²⁰¹, X²⁰², m201or p201 contained in one molecule may be the same or different), whereinin —CO—R³⁵ and —CO—Z, Z represents a monovalent aliphatic hydrocarbongroup having a carbon number of 1 to 25, in which a part of carbon atomsmay be substituted with a heteroatom, or a monovalent aromatichydrocarbon group having a carbon number of 4 to 25, which may have asubstituent, and R³⁵ represents a group represented by any one of thefollowing formulae (18) to (20):

(in formula (18), R⁴¹ represents a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom, and each of R⁴² toR⁴⁴ independently represents an alkyl group having a carbon number of 1to 25, in which a part of carbon atoms may be substituted with aheteroatom, or a benzyl group; in formula (19), any one of R⁴⁵ to R⁵⁰represents a direct bond or a divalent aliphatic hydrocarbon grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom, provided that in the case where R⁴⁵ isa direct bond or a divalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, each of R⁴⁶ to R⁵⁰ independently represents ahydrogen atom, a halogen atom, a cyano group, a nitro group, an alkylgroup having a carbon number of 1 to 25, in which a part of carbon atomsmay be substituted with a heteroatom, a phenyl group, a phenoxy group,an N-alkylcarbamoyl group or an N-alkylsulfamoyl group, and in the casewhere any one of R⁴⁶ to R⁵⁰ is a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom, each of the otherfour independently represents a hydrogen atom, a halogen atom, a cyanogroup, a nitro group, an alkyl group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom, aphenyl group, a phenoxy group, a benzyl group, an N-alkylcarbamoyl groupor an N-alkylsulfamoyl group, and R⁴⁵ represents an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, or a benzyl group; and in formula (20),any one of R⁵¹ to R⁵⁵ represents a direct bond or a divalent aliphatichydrocarbon group having a carbon number of 1 to 25, in which a part ofcarbon atoms may be substituted with a heteroatom, provided that in thecase where either one of R⁵¹ and R⁵³ is a direct bond or a divalentaliphatic hydrocarbon group having a carbon number of 1 to 25, in whicha part of carbon atoms may be substituted with a heteroatom, the otherrepresents an alkyl group having a carbon number of 1 to 25, in which apart of carbon atoms may be substituted with a heteroatom, or a benzylgroup, and each of R⁵², R⁵⁴ and R⁵⁵ independently represents a hydrogenatom, a halogen atom, a cyano group, a nitro group, an alkyl grouphaving a carbon number of 1 to 25, in which a part of carbon atoms maybe substituted with a heteroatom, a phenyl group, a phenoxy group, abenzyl group, an N-alkylcarbamoyl group or an N-alkylsulfamoyl group,and in the case where any one of R⁵², R⁵⁴ and R⁵⁵ is a direct bond or adivalent aliphatic hydrocarbon group having a carbon number of 1 to 25,in which a part of carbon atoms may be substituted with a heteroatom,each of the other two independently represents a hydrogen atom, ahalogen atom, a cyano group, a nitro group, an alkyl group having acarbon number of 1 to 25, in which a part of carbon atoms may besubstituted with a heteroatom, a phenyl group, a phenoxy group, a benzylgroup, an N-alkylcarbamoyl group or an N-alkylsulfamoyl group, and eachof R⁵¹ and R⁵³ independently represents an alkyl group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a benzyl group; the total number of carbon atomscontained in R⁴¹ to R⁴⁴ in formula (18) is 20 or more, the total numberof carbon atoms contained in R⁴⁵ to R⁵⁰ in formula (19) is 15 or more,and the total number of carbon atoms contained in R⁵¹ to R⁵⁵ in formula(20) is 17 or more; and R⁴¹ to R⁵⁵ may combine in the same compound toform a ring).
 22. The composition as claimed in claim 21, wherein saidepoxy compound α is a compound represented by any one of the followingformulae (13) to (15):(A¹)-(OG)_(m1)  (13) (in formula (13), G represents a glycidyl group(2,3-epoxypropanyl group), and said glycidyl group may be substitutedwith an alkyl group, a phenyl group or an alkoxycarbonyl group; A¹represents an m1-valent aromatic or aliphatic hydrocarbon group that mayhave a substituent; and m1 represents an integer of 1 or more; providedthat a plurality of G contained in one molecule may be same ordifferent);(GO)_(m2)-(A²¹)-[X²-(A²²)]_(n2)—X²-(A²¹)-(OG)_(m2)  (14) (in formula(14), G represents a glycidyl group, and said glycidyl group may besubstituted with an alkyl group, a phenyl group or an alkoxycarbonylgroup; A²¹ represents an (m2+1)-valent aromatic or aliphatic hydrocarbongroup that may have a substituent; A²² represents a divalent aromatic oraliphatic hydrocarbon group that may have a substituent; the A²¹ and A²²connected through X² or a plurality of adjacent A²² may combine witheach other to form a ring; X² represents a direct bond or a divalentlinking group that may have a substituent; m2 represents an integer of 1or more; and n2 represents 0 or an integer of 1 or more; provided that aplurality of G, A²¹, A²², X² or m2 contained in one molecule may be sameor different);H—[(A³(OG)_(m3))—X³]_(n3)—H  (15) (in formula (15), G represents aglycidyl group, and said glycidyl group may be substituted with an alkylgroup, a phenyl group or an alkoxycarbonyl group; A³ represents an(m3+2)-valent aromatic or aliphatic hydrocarbon group that may have asubstituent; X³ represents a direct bond, an alkylene group that mayhave a substituent, or —R⁴¹-phenylene-R⁴²—, wherein each of R⁴¹ and R⁴²independently represents an alkylene group; m3 represents an integer of1 or more; and n3 represents an integer of 2 or more; provided that aplurality of G, A³, X³ or m3 contained in one molecule may be same ordifferent).
 23. The composition as claimed in claim 21, wherein theabundance ratio of said compound β to said epoxy compound α contained insaid composition is from 0.05 to 10.0 mol %.
 24. The composition asclaimed in claim 21, wherein said compound β is a compound where informula (13) to (15) or (32), one or more -OG groups are substitutedwith a group represented by the following formula (16) or (17) and oneor more -OG groups may be substituted with a group represented by thefollowing formula (33):

(in formula (16), R³⁵ represents a group represented by any one of theformulae (18) to (20) as described above; and in formula (17), Zrepresents a monovalent aliphatic hydrocarbon group having a carbonnumber of 1 to 25, in which a part of carbon atoms may be substitutedwith a heteroatom, or a monovalent aromatic hydrocarbon group having acarbon number of 4 to 25, which may have a substituent).
 25. The methodfor producing an epoxy compound as claimed in claim 6, wherein in saidproduction method, after the reaction, said substituent convertible toan active hydrogen-containing functional group or a salt thereof ishydrolyzed with a basic compound.